Automated Aircraft Composite Repair

Reduce defects and performs complex repairs 50% faster. No mylar, scissors, or razor blades required.

PlyGage is an automated composite repair system that streamlines and improves the quality of complex or large carbon fiber repairs by automating ply tracing, ply cutting, and ply lay-up. PlyGage is a 3D digital composite repair solution. It streamlines the repair process, starting with the repair scarf and ending with a completed repair. This means all of the functions historically performed with mylars, markers, scissors, knives, and templates are brought into the digital realm. The entire process is so fast and easy that your current repair personnel can use Plygage.

Ply Tracing is performed over a 3D surface measurement of the scarf. The 3D scarfed surface is measured directly by PlyGage. Plies can be drawn on the computer with a mouse, detected automatically from the camera images, or imported from a template. Plygage supports all normal editing operations including spline drawing, polyline drawing, auto closing, grow, shrink, copy, and move. You don’t have to trace plies with a marker on mylar.

Ply Cutting is performed with an off-the-shelf carbon fiber cloth and fabric cutting systems. Ply cutting with scissors is eliminated. PlyGage flattens the 3D plies to 2D, rotates them to match correct fabricate orientation, and exports industry standard IGES or DXF files for nesting. We have successfully integrated with TruNest (R) and ComposiNest (R). Plygage can support other nesting packages with minimal effort.

Ply Layup is assisted by the built-in video projector. PlyGage accurately projects the ply location, ply orientation, and ply name directly onto the scarf, all in color. PlyGage indicates the location on the ply to start the lay-up, reducing the difficulty in laying up over complex curved surfaces. There is no need to flip a mylar sheet on and off the repair during lay-up.

Documentation is automatically generated as part of the process. The documentation includes the fully digital flattened 2D DXF or IGUS files, a material summary report, images of the scarf with the plies drawn on them, a properly scaled PDF file (that can be printed and used as a substitute for mylar), and an XML file that makes it easy to develop customer-specific hooks and reports.


Plygage process map


A ply scan for repair in its native shape.


A sample of a PlyGage repair.


A PlyGage Portable System.