Manufacture of complex composite parts

1. Automated method for manufacturing layer by layer a composite part with rotational symmetry and complex cross-section, the method for manufacturing each layer comprising the steps of:

a) continuously unwinding a reinforcement ( 1 , 11 ) from one of a reel or roll, said reinforcement being one of dry or pre-impregnated;

b) impregnating the reinforcement with a liquid resin by passing the reinforcement through a bath ( 2 ) when the reinforcement of step a) is dry;

c) continuously winding the impregnated or pre-impregnated reinforcement ( 22 ) onto a rotating cylindrical mandrel ( 4 );

d) at least partially polymerizing the impregnated or pre-impregnated reinforcement ( 22 ) in order to obtain a layer of composite material ( 20 );

e) continuously depositing a removable support ( 21 , 9 ) on both sides of the layer of composite material ( 20 ) being disposed onto the rotating cylindrical mandrel ( 4 ) to fill gaps surrounding the composite part.

2. Automated method of manufacture as in claim 1 , wherein the reinforcement ( 11 ) is one of a fabric or a braid.

3. Automated method of manufacture as in claim 1 , further comprising the step of automatically cutting the reinforcement ( 11 ) respectively into strips called reinforcement strips ( 15 ) and into strips called offcut strips ( 16 ) of a width that varies according to the geometry of the part to be produced after the step of continuously unwinding the reinforcement ( 1 , 11 ) from one of a reel or roll.

4. Automated method of manufacture as in claim 1 , wherein, during the step of at least partially polymerizing the impregnated or pre-impregnated reinforcement ( 22 ), a heating by a Joule effect of the impregnated or pre-impregnated reinforcement ( 22 ) is performed by means of a variable magnetic field applied to the part being produced.

5. Automated method of manufacture as in claim 2 , further comprising the step of stitching the impregnated or pre-impregnated reinforcements partially polymerised in step d), said stitching occurring in a direction that is perpendicular to the layers of the composite material ( 20 ).

6. Automated method of manufacture as claim 1 , wherein, when the manufacturing layer by layer of the composite part is finished, there is an additional step of post-polymerisation.

7. Automated method of manufacture as in claim 1 , wherein the resin is a thermosetting resin being catalysed by means of a photo-initiator or a thermo-initiator.

8. Automated method of manufacture as in claim 1 , further comprising the step of removing the support ( 21 , 9 ) from said part and removing said part from the cylindrical mandrel ( 4 ).

9. Automated method of manufacture as in claim 3 , wherein the support ( 21 ) comprises the offcut strips ( 16 ) impregnated with a support material ( 9 ).

10. Automated method of manufacture as in claim 9 , wherein the impregnation of the offcut strips ( 16 ) occurs in parallel with the step of impregnating the reinforcement with a liquid resin.

11. Automated method of manufacture as in claim 1 , wherein the deposition of the support material ( 9 ) is carried out by atomization of fine droplets by means of a spray head ( 6 ), said support material ( 9 ) being in liquid form with a viscosity that is suitable for spraying.

12. Automated method of manufacture as in claim 1 , wherein the step of at least partially polymerizing includes initiating cross linking of the resin with one of ultraviolet or infrared radiation ( 5 ).