CAD/CAM Net Shape Weaving

For diverse applications, and in particular for fiber reinforced composites, it is desirable to have the freedom of specifying both the warp and the weft direction and density according to the load distribution on the end product. Curvature of the fabric can be using variable coned take up rollers that can be electronically slaved to the main master loom drive this will enable the fabric to curve at any programmable radius, progressively, to both the right (+) and the left (-) directions. Using linear servo actuators it is possible to change the radius progressively to any desired value. Variable spaced and variable width reeds along with the weft insertion to match the variable width will enable the weaving of different warp densities and fabric widths. An alternative method utilizes horizontal spring supported individual reed wires that change their relative positions by means of a mechanical linear actuator driven by a servo motor, that is slaved to the main master loom drive. Encoded servo drives are becoming common and inexpensive. With the advance of the personal computer (PC) and multi-axis plug in motion control cards combined with user friendly software this option has become a reality that brings together all the ingredients of the desired loom. The above principles can be superimposed on any loom frame desired, although due to the phase I requirement for loom delivery within 6 months, an existing reconditioned flat loom will be used. Federal Fabrics-Fibers (FFF) has converted looms to include computer controlled variable cones that can change progressively and on the fly. In addition, the entire loom drive and actuators is also computer controlled. This system is modular and upgradable to future additional axis's for weft density and width control. Composite structures are the key to reduce weight of any structure, mobile or stationary. Rapid deployment requires light weight structures. The automotive partnership for new generation vehicle (PNGV) appears to embrace composites as one way to keep the competitive edge. The use of composites materials will result in weight reduction reduced fuel consumption, and lower emissions. Composites are all around us from utility pipes and