Material preparation device and related methods

1. A bias-ply material preparation device, the device comprising:

a backing material assembly configured to pass bias-ply backing material along a first path, wherein the bias-ply backing material is configured to be removed from the bias-ply material;

an application assembly configured relative to the bias-ply backing material, the application assembly configured to:

apply a first section of fiber-reinforced material feedstock directly on the bias-ply backing material in a forming area at a first angle relative to the first path;

cut off the first section of fiber-reinforced material feedstock;

move the first section of fiber-reinforced material feedstock at least partially out of the forming area with the bias-ply backing material; and

apply at least a second section of fiber-reinforced material feedstock directly on the bias-ply backing material at the first angle relative to the first path in the forming area to prepare the bias-ply material.

2. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at various angles relative to the first path.

3. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at an oblique angle relative to the first path.

4. The device of claim 1 , wherein the application assembly is configured to position the fiber-reinforced material feedstock at a perpendicular angle relative to the first path.

5. A method of preparing a fiber-reinforced material for use with a composite structure, the method comprising:

passing a bias-ply backing material along a first path with a backing material assembly, wherein the bias-ply backing material is configured to be removed from the fiber-reinforced material for use with a composite structure;

applying a first section of fiber-reinforced material directly on the bias-ply backing material in a forming area at a first angle relative to the first path;

cutting off the first section of fiber-reinforced material;

moving the first section of fiber-reinforced material at least partially out of the forming area with the bias-ply backing material; and

applying at least a second section of fiber-reinforced material directly on the bias-ply backing material in the forming area at the first angle to prepare the fiber-reinforced material for use with a composite structure.

6. The method of claim 5 , further comprising orienting the first angle in a direction offset from the first path.

7. The method of claim 5 , further comprising orienting the first angle at an oblique angle relative to the first path.

8. The method of claim 5 , further comprising orienting the first angle at a perpendicular angle relative to the first path.

9. The method of claim 5 , further comprising overlapping the first section of fiber-reinforced material and the at least a second section of fiber-reinforced material.

10. The method of claim 5 , further comprising positioning the at least a second section of fiber-reinforced material adjacent the first section of fiber-reinforced material with no overlap.

11. The method of claim 5 , further comprising defining a fabric with at least the first section of fiber-reinforced material and the at least a second section of fiber-reinforced material.

12. The method of claim 5 , further comprising applying a layer of fiber-reinforced material over the first section and the at least a second section at a second angle relative to the first path, wherein the first angle and the second angle are offset from each other.

13. A material preparation device, the device comprising:

a substrate assembly configured to pass a base substrate along a first path; and

a movable application assembly carrying a supply of fiber material feedstock, the movable application assembly configured to move relative to the base substrate to apply a layer of the fiber material feedstock comprising multiple individual sections of the fiber material feedstock directly on the base substrate at an offset angle relative to the first path; and

wherein the base substrate is configured to be removed from the layer of fiber material feedstock.

14. The device of claim 13 , wherein the movable application assembly is configured to apply a first individual section of fiber material feedstock directly on the substrate at a position adjacent to a second individual section of fiber material feedstock.

15. The device of claim 14 , wherein the material preparation device is configured to connect the first individual section to the second individual section of fiber material feedstock to define a sheet of fiber material.

16. The device of claim 13 , wherein the movable application assembly is configured to apply the layer of fiber material feedstock comprising fibers in at least some resin.

17. A method of preparing a fiber-reinforced material for use with a composite structure, the method comprising:

passing a base substrate along a first path with a substrate assembly wherein the base substrate is configured to be removed from the fiber-reinforced material for use with a composite structure;

applying a first layer of fiber material directly on the substrate at an offset angle relative to the first path with a movable application head; and

applying a second layer of fiber material directly on the substrate at a position adjacent to the first layer of fiber material with the movable application head.

18. The method of claim 17 , further comprising applying a third layer of fiber material on the substrate at a position adjacent to the second layer of fiber material feedstock with the movable application head.

19. The method of claim 18 , further comprising connecting the first layer, the second layer, and the third layer to define a sheet of fiber material.

20. The method of claim 18 , further comprising connecting the first layer, the second layer, and the third layer with a tape material to define a sheet of fiber material.

21. The method of claim 18 , further comprising selecting the first layer, the second layer, and the third layer of the fiber material to comprise fibers in at least some resin.