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Comprehensive Solutions for Automated Composites Processing

MAG Cincinnati is the total solutions provider for automated composites

processing. With nearly 100 installations around the world, we have more

tape layers and ber placement systems in operation than the com-

bined total of all other suppliers of this equipment.

Expanding Into Growing Composites Markets

The strength, durability and versatility of composites have been recognized

in other key manufacturing sectors including energy, automotive and con-

struction. MAG Cincinnati is leveraging our vast experience and processing

expertise to serve these new composites markets.

Today, MAG Cincinnati customers achieve superior production rates

combined with the industrys highest compaction forces to produce a wide

variety of aerospace parts including:

, Fuselages

, Wings

, Engine nacelle components

, Horizontal and vertical stabilizers

, Military aircraft inlet ducts

, Satellite launch vehicle components

02 | 03

MAG Cincinnati has the worlds largest installed base. Here is a sample of the types of aircraft programs we have supplied equipment for.

MAG CINCINNATI COMPOSITES SYSTEMS 20+ MAJOR AEROSPACE PROGRAMS

MAG Cincinnati is the Supplier-of-Choice to leading aircraft producers

around the world. Whether choosing automated composites processing

equipment or related machine tools such as robust, titanium processing

machines or specialized equipment, our equipment achieves superior

results.

Australia Hawker de Havilland

Belgium SABCA

Brazil Embraer Air, General Electric

Canada Bombardier, NRC Institute,

Magellan Aerospace, Heroux-Devtek

China Chengdu Aircraft, Shanghai Aircraft,

Xian Aero Engine, Xian Aircraft,

Shenyang Aircraft, Liyang Aero Engine

France Airbus

Germany Airbus

Hungary General Electric

Indonesia IPTN

Israel Israel Aerospace Industries

Italy Alenia

Japan Fuji Heavy Industries,

Kawasaki Heavy Industries,

Mitsubishi Heavy Industries

Korea Korea Aerospace Industries, Korean Airlines

Spain Airbus, EADS CASA

UK Airbus, BAE Systems, Bombardier,

Magellan, Rolls-Royce

USA ATK, Bell Helicopter, Boeing, General Electric,

GKN Aerospace, Giddens Industries,

Goodrich, Hawker Beechcraft, HITCO,

Lockheed Martin, NASA, Northrop Grumman,

Raytheon, Spirit Aerospace, Vought Aircraft

Improving Your Bottom Line With Automated Composites Processing

Prominent aerospace manufacturers rely on our highly reliable equipment

and unmatched process experience to achieve these benets of automated

lamination:

, Component design optimization by utilizing simulations

, Reduced weight and assembly cost

, Reduced labor costs per component

, Reduced in-process inspection costs

, Reduced material scrap

, Reduced re-work

, Elimination of kitting

MAG Cincinnati not only supplies highly reliable and productive equipment but we also provide access to the industrys most comprehensive solution to support the entire automated process

SUPPORTING THE ENTIRE COMPOSITE MANUFACTURING PROCESS

CHARGER Tape Layers

MAG Cincinnati CHARGER Tape Layers achieve high-speed, precision lay-up

that helps accelerate work flow to shorten build schedules and reduce

work-in-process costs. This newest generation of MAG Cincinnati tape

layers, the CHARGER Series, is engineered for world-class throughput with

faster lay-up and easier, quicker setup. The CHARGER Series lay 75, 150

or 300 mm (3, 6 or 12 in.) carbon/epoxy tape with any orientation and num-

ber of plies, assuring consistent quality part shape, thickness, and strength.

Parts can be laid up over tool surfaces with contours, flats, and changing

geometries, bringing exibility and precision to the most complex jobs.

MAG Cincinnati has more than 25 years of experience in manufacturing

automated tape laying equipment. The new CHARGER Tape Layers utilize

proven machine components combined with patented features designed

specically to improve overall performance while maintaining superior

reliability. CHARGER Tape Layers are offered with a choice of advanced

technologies needed for high production tape laying including:

, Vacuum lay-up tables

, Ultrasonic laminate cutting

, Integral inkjet marking

, Tape steering

, CM100 computer control

, ACES off-line software

04 | 05

CHARGER Tape Layers accommodate 300 mm (12 in.) wide tape lay-up on contoured surfaces with segmented compactor or conformable roller

Tape can be steered along a path that is not the natural path that the tape wants to follow on a complex contoured surface

An ultrasonic cutter integrated with the tape head eliminates the need to transfer and re-align laminates onto a separate cutting machine

The tape head removes the optional inkjet marker from its docking station to mark white patterns directly onto the uncured laminate

CHARGER Tape Layers

Segmented shoe allows tape laying with minimum use of roller for less risk of contamination

High mold clearance design provides superior conformance and compac-tion on ramps and joggles

New tape head accommodates fast loading via open sided supply reel and is capable of laying wrinkle-free 300 mm (12 in.) tape on contours

New Contour Tape Head

Recently re-engineered for easier set-up and operation, the new contour

tape head contributes to the machines, higher total throughput. The head

allows faster, simpler side-loading of tape rolls up to 300 mm (12 in.) wide

and 650 mm (25.6 in.) diameter. Common hardware permits lay-up of

75 mm (3 in.), 150 mm (6 in.) and 300 mm (12 in.) wide tape with minimal

changeover time. The advanced head design also features integrated ultra-

sonic laminate cutting, cutter depth-setting assistance, and dockable inkjet

marking for maximum system exibility and performance.

MAG Cincinnatis CHARGER Series includes both Contour and Flat

Tape Layers available in High Rail, Low Rail and Bed Type congurations to

meet production and facility requirements.

CHARGER Bed-Type Contour Tape Layers achieve up to 25 degree

contours while delivering 50 m/min. (2000 ipm) lay-up rate. The machines

feature MAG Cincinnatis newest generation tape head which is the mar-

kets most productive and consistent at compacting layers of carbon/epoxy

tape.

CHARGER Flat Tape Layers are excellent for high productivity lay-up

of large laminates that are then cut into smaller pieces and drape formed.

These machines feature programmable compaction force and optional

vacuum lay-up/cutting tables and ultrasonic laminate cutting enabling

superior quality and performance.

.

CHARGER Tape Layers

06 | 07

NEW Small Flat Tape Layer

MAG Cincinnati now offers a new, entry-level tape layer. This newest

member of the CHARGER Series is designed and built to migrate proven

modules and technologies from our larger composites products to an

affordable, right-sized, yet extremely productive new platform. The Small

Flat Tape Layer with its simplied, but versatile tape head and integral vacuum

lay-up table is well-suited for new users that are making the transition

from hand lay-up as well as for those users that are already experienced in

automated lamination.

Expanded Product Range

To meet the demand for utilizing composite materials for long structural

parts such as stringers, spars and beams MAG Cincinnati has expanded

its tape layer product range to include a new platform, the Flat Charge

Laminator. The Flat Charge Laminator is designed specically to optimize

processing of these long, narrow parts by accommodating ATL grade

prepreg material up to 300 mm (12 in.) in width while utilizing high-capacity

laminating heads in combination with a heavy-duty support structure for

carriage and segmented vacuum table. The multi-headed design can lay

prepreg unidirectional tape, prepreg woven fabric, and lm/foil in the same

variable thickness laminate.

Typical Tape Layer Applications

, Wing skins

, Control surfaces such as aps, ailerons, elevators and rudders

, Structural components such as stringers, spars, beams and shear ties

, Horizontal and vertical stabilizers

, Fuselage panels

, Fairings

, Satellite antenna panels

, Bulkhead

The unit is equipped with features designed for fast, error-free production

VIPER Fiber Placement Systems

Get the VIPER Advantage

With 7 axes of motion, VIPER Fiber Placement Systems are particularly

suited to highly contoured structures. High contour, variable wall thickness,

and cut-out sections are all produced to near net configuration which

signicantly reduces material waste (as low as 2%) in the initial lay-up and

post-process machining operations.

VIPER Fiber Placement Systems automatically and independently control

up to 32 individual tows or slit tape producing a variable bandwidth

on-the-y. Each tow can be independently dispensed, clamped, cut and

restarted during ber placement. Gaps and overlaps are minimized as the

machine precisely lays interior or exterior contoured boundaries.

The VIPERs advanced design delivers other key advantages to automated

production including maintaining constant angle on a complex surface,

in-process compaction of material and no limits to ply orientations.

MAG Cincinnati VIPER Fiber Placement Systems are the most

versatile and advanced composites manufacturing equipment in production

today. The VIPER platform of machines combines the advantages of tape

laying and lament winding with advanced computer control and software to

achieve unmatched production capabilities for a wide variety of complex

composites parts. Offered in a variety of sizes, 1200, 4000 and 6000,

VIPER Fiber Placement Systems are designed for dexterity and exibility

for production of wrinkle-free lay-up of convex and concave parts. These

highly productive machines are equipped with patented features to produce

superior quality while dramatically reducing scrap.

These patented features include:

, Segmented Compaction Roller offers superior compaction on core

and tight radii contour surface features

, Bi-directional Tensioners located in the creel enclosure maintain

precise tension control of each tow as well as monitor the individual

pay-out of each

, Re-direct Roller Systems reduces the likelihood of twisted tows by

maintaining a at ber band

, Individual Tow Cut-Clamp-Restart adds versatility by adjusting the

width of the ber band by adding or cutting individual tows on-the-y

Individual Tows (x32) 3.2 mm (0.125 in.) 6.4 mm (0.25 in.) 12.7 mm (0.5 in.)Collimated Fiber Band 102 mm (4 in.) 205 mm (8 in.) 406 mm (16 in.)

08 | 09

VIPER Fiber Placement Systems

VIPER 1200

, Part diameters up to 2 m (80 in.)

, 12 tows; 3.2 or 4.0 mm (0.125 or 0.157 in.)

VIPER 4000

, Part diameters up to 6 m (236 in.)

, 24 or 32 tows; 3.2 or 6.4 mm (0.125 or 0.25 in.)

VIPER 6000

, Part diameters up to 8 m (315 in.)

, 32 tows; 3.2, 6.4 or 12.7 mm (0.125, 0.25 or 0.5 in.)

Expanded Product Range

The VIPER 4000 is the newest machine in our VIPER Series of ber

placement systems. This machine offers high dexterity and clearance for

lay-up on female molds. The new VIPER 4000 utilizes standard compo-

nents from MAG Cincinnatis VIPER 6000 platform combined with special

features to deliver unmatched dexterity and exibility in processing medium

to large contoured parts. The machine offers unprecedented ease-of-use

and is capable of processing a wide range of composites parts up to 6 m

(236 in.) diameter utilized in todays new aircraft designs. In particular the

VIPER 4000 is well-suited for producing fuselages for both regional and

business jets as well as engine nacelles.

VIPER Applications

VIPER Fiber Placement Systems deliver proven fuselage production

capabilities from the smallest business jet to the worlds largest commercial

aircraft. Hawker Beechcrafts Premier 1 Business Jet is made of two 360

fuselage sections produced on a VIPER Fiber Placement System. The

composite fuselage design is 20% lighter than aluminum and reduces the

number of parts from the original 3000 to two.

Other VIPER Applications

, Wing skins

, Nacelles

, Inlet ducts

, Launch vehicle components

NEW

NEW

All skin panels for Sections 19 & 19.1

of the Airbus A380 are made on

VIPER Fiber Placement Systems.

Powerful Control and Software

MAG Cincinnati leads the industry with control and off-line programming

software platforms compatible with both our CHARGER Tape Layers and

VIPER Fiber Placement Systems.

Powerful CM100 Control

MAG Cincinnatis CM100 computer control is the only control designed

specically for automated composites production. This powerful, yet

extremely easy-to-use control features an open-architecture design

powered by industrial grade processors and digital servo drives to deliver

fast, smooth and accurate machine motion.

The CM100 provides coordinated motion of all machine and head axes

and controls all dispensing functions to accurately place the composite

material onto the lay-up surface with programmable compaction control.

The highly rated, operator-friendly CM100 executes part programs without

requiring a separate PC to serve as a front end processor, and it complies

with all applicable industry standards, including CE Mark requirements.

The CM100 utilizes 100% standard commercial hardware which includes

a large 19 inch color touch screen monitor, industrial keyboard, and

pointing device. MAG Cincinnatis proprietary control software enables

multi-level password access, multiple display pages and menus, real-time

combined diagnostic displays, and exclusive push button history. The

Observer Part History software included with the CM100 gathers and

reports manufacturing data that can be used to optimize the lamination

process for maximum system productivity. Data access is provided

through standard Windows network utilities and optional OPC Server.

With the largest number of users worldwide, our ACES off-line programming software consistently receives superior customer satisfaction ratings

ACES Advanced Composites Environment Suite

ACES is MAG Cincinnatis proprietary programming and simulation

software tool for tape laying and ber placement. This powerful suite is

PC-based, compatible with CATIA V4 and V5, CATIA CWB/CD3, and

FiberSIM, and provides a variety of path generation types. ACES supports:

part programming, part simulations, productivity analysis and production

animations.

Optimized Cutting Performance

10 | 11

High-Speed Aluminum Cutting

MAG Cincinnati offers the broadest range of products for high-speed

processing of aluminum. Our equipment can be found in production across

the globe processing thin wall aluminum components of all shapes and

sizes. The HyperMachTM linear motor profiler is achieving the highest metal

removal rates in production 7538 cm3/min. (460 in3/min.).

Specialized Tooling Solutions

Through our award-winning service and support organization, MAG Mainte-

nance Technologies, MAG Cincinnati exclusively offers specialized Technicut

cutting tool solutions for machining aerospace alloys and composite materials.

Together, we are setting new benchmarks for composite and metal removal

rates throughout the aerostructure and aeroengine markets.

With over 20 years experience of composite machining methodologies,

Technicut has the capability to manufacture optimized tooling solutions

which prole, surface machine, rout, contour, and produce holes in all

composite materials. Technicut designs and manufactures solid carbide,

brazed carbide, high speed steel, and polycrystalline diamond roughing and

nishing tools for a diverse array of materials and machining applications

ranging from titanium blisks, blades and impellers to titanium and aluminum

monolithic solid aerostructures.

MAG Cincinnati designs and builds a wide range of highly reliable

machine tools utilizing features that optimize cutting performance. Whether

youre machining composite, titanium, steel, nickel alloys, or aluminum,

we have the equipment that delivers long-term, high productivity operation.

MAG Cincinnati offers processing expertise and machining techniques wing

drilling and forward fuselage system performs automated drilling to drill and

countersink fastener holes on the outer skin and substructure of the upper

and lower surfaces of the wing and forward fuselage cockpit side panel for

F-35 (Joint Strike Fighter) aircraft.

Waterjet Cutting

Waterjet cutting is one of the best methods for cutting composite material,

hard metals and high temperature resistant material. MAG Cincinnati offers

a highly reliable system that is in production manufacturing composite skins

and structural parts at leading manufacturers around the world.

Titanium and Hard Metal Cutting

Titanium brings tremendous advantages to aircraft construction

compatibility with composite materials, light weight, great stiffness,

strength, as well as being heat- and fatigue-resistant. MAG Cincinnati

provides robust machine tools combined with expertise in helping

customers select tools, xtures and machining techniques all critical

elements in machining titanium.

Wing drilling systems

Titanium cutting

Waterjet cutting

High-speed cutting

Composite tooling solutions Metalcutting tooling solutions

Automated Assembly, Systems Integration and Testing

Conveyance

End of arm tooling (EOAT)

Forming press

Automated Assembly, Systems Integration and Testing

World-class producers of aircraft and aircraft components are now seeing

the cost savings and accuracy improvements that can be achieved utilizing

manufacturing practices that were once only used in automotive manufac-

turing. MAG Cincinnati Automation business is leveraging its automotive

expertise to tailor solutions for the aerospace industry. We have successfully

designed, built and installed systems for some of the most respected aero-

space manufacturers. MAG Cincinnati Automation offerings include material

handling, composite forming, robots and xturing solutions employing

standard, exible or customized solutions to satisfy specic manufacturing

challenges and ergonomic needs.

MAG Cincinnati Automation has more than 30 years of experience with over

2500 installations worldwide. We offer a complete range of products from

machining to assembly to automation.

Proven Aerospace Solutions

1 Material Handling: conveyor & transfer mechanisms, including

gantry, pick and place and conveyance

2 Detail Part Manufacture: manufacture and fabrication of raw

Material: components include rib, skin, stringer, spar, bladder, floor

beams and panels

3 Robotics: drill, riveting, sealant application for wing and fuselage

assembly End of Arm Tooling (EOAT)

More Process Experience from MAG Cincinnati Automation

, Leak testing , Marking

, Vision , Servo control

, Laser applications , Signature analysis

, Ultrasonic welding , Heavy duty pressing

, Splicing/cut-off , Resistance welding

, Web handling/converting , Torqueing

, Riveting , Gauging

, Dispensing

1

2

3

MAG Cincinnati

Cincinnati Machine, LLC

2200 Litton Lane

Hebron, KY 41048

USA

tel +1 859 534 4600

fax +1 859 534 4995

www.cinmach.com

For information regarding local

addresses and partners visit

w w w. m a g - i a s . c o m

The machines shown are examples. Actual machines may vary based on selected options.

Going straight to the top with MAG

thats the opportunity offered by

the technology leading companies

in our group.

Through our commitment and in-

novative power, we steer a broad

range of industrial manufacturing

companies to success. Our reach

extends across the globe as we

help the wheels of progress to

turn faster.

MAG Cincinnati, a leading supplier of innovative production machinery for

nearly 125 years, designs and builds a broad range of machine tools and

related equipment including Vertical Machining Centers, Horizontal Machining

Centers and Cells, Universal Machining Centers, Prolers, Automated Composites

Processing Equipment and Special Machines. Our well-equipped products

combined with extensive process knowledge deliver superior industry results

for the aerospace, heavy equipment, energy and general machining markets.

Since 2005 MAG Cincinnati has been a part of MAG Industrial Automation

Systems, a dynamically expanding group that has achieved a leading position

in the global machine tool manufacturing industry. With its innovative, highly

productive machine solutions MAG is a strong partner for the metalworking

industries in the aerospace, machining, automotive, heavy equipment and

energy sectors. A growing number of leading international companies are

relying on the impressive innovative power of the MAG group to assure their

technological leadership and prepare for future challenges.