COMPOSITES

SOLUTIONS FOR AUTOMATED COMPOSITES PROCESSING

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 fiber placement systems in operation than the combined
total of all other suppliers of this equipment.
Expanding Into Growing Composites Markets
Today, MAG Cincinnati customers achieve superior production rates
combined with the industry’s 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
The strength, durability and versatility of composites have been recognized
in other key manufacturing sectors including energy, automotive and construction.
MAG Cincinnati is leveraging our vast experience and processing
expertise to serve these new composites markets.
MAG Cincinnati has the world’s 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
02 | 03

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 benefits 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
SUPPORTING THE ENTIRE COMPOSITE MANUFACTURING PROCESS
MAG Cincinnati not only supplies highly reliable and productive equipment but we also
provide access to the industry’s most comprehensive solution to support the entire
automated 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 number
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 flexibility and precision to the most complex jobs.
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
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
specifically 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:
An ultrasonic cutter integrated with the tape head eliminates the need
to transfer and re-align laminates onto a separate cutting machine
, Vacuum lay-up tables
, Ultrasonic laminate cutting
, Integral inkjet marking
, Tape steering
, CM100 computer control
, ACES ® off-line software
The tape head removes the optional inkjet marker from its docking
station to mark white patterns directly onto the uncured laminate
04 | 05

CHARGER Tape Layers
MAG Cincinnati’s CHARGER Series includes both Contour and Flat
Tape Layers available in High Rail, Low Rail and Bed Type configurations to
meet production and facility requirements.
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 ultrasonic
laminate cutting, cutter depth-setting assistance, and dockable inkjet
marking for maximum system flexibility and performance.
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 Cincinnati’s newest generation tape head which is the market’s
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.
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
.
High mold clearance design provides superior conformance and compaction
on ramps and joggles
Segmented shoe allows tape laying with minimum use of roller for less
risk of contamination

CHARGER Tape Layers
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 simplified, 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 specifically 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 film/foil in the same
variable thickness laminate.
The unit is equipped with features designed for fast, error-free production
Typical Tape Layer Applications
, Wing skins
, Control surfaces such as flaps, 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
06 | 07

VIPER ® Fiber Placement Systems
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 filament 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 flexibility
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 flat fiber band
, Individual Tow Cut-Clamp-Restart adds versatility by adjusting the
width of the fiber band by adding or cutting individual tows on-the-fly
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
significantly 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-fly”. Each tow can be independently dispensed, clamped, cut and
restarted during fiber placement. Gaps and overlaps are minimized as the
machine precisely lays interior or exterior contoured boundaries.
The VIPER ® ’s 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.
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.)

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.)
NEW 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.)
NEW Expanded Product Range
The VIPER ® 4000 is the newest machine in our VIPER ® Series of fiber
placement systems. This machine offers high dexterity and clearance for
lay-up on female molds. The new VIPER ® 4000 utilizes standard components
from MAG Cincinnati’s VIPER ® 6000 platform combined with special
features to deliver unmatched dexterity and flexibility 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 today’s 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 world’s largest commercial
aircraft. Hawker Beechcraft‘s 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.
All skin panels for Sections 19 & 19.1
of the Airbus A380 are made on
VIPER ® Fiber Placement Systems.
Other VIPER ® Applications
, Wing skins
, Nacelles
, Inlet ducts
, Launch vehicle components
08 | 09

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 Cincinnati’s CM100 computer control is the only control designed
specifically 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 Cincinnati’s 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.
ACES ® – Advanced Composites Environment Suite
ACES ® is MAG Cincinnati’s proprietary programming and simulation
software tool for tape laying and fiber 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.
With the largest number of users worldwide, our ACES ® off-line programming software
consistently receives superior customer satisfaction ratings

Optimized Cutting Performance
MAG Cincinnati designs and builds a wide range of highly reliable
machine tools utilizing features that optimize cutting performance. Whether
you’re 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.
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 HyperMach TM linear motor profiler is achieving the highest metal
removal rates in production – 7538 cm 3 /min. (460 in 3 /min.).
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, fixtures and machining techniques – all critical
elements in machining titanium.
Specialized Tooling Solutions
Through our award-winning service and support organization, MAG Maintenance
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.
Composite tooling solutions
Metalcutting tooling solutions
Wing drilling systems
Waterjet cutting
With over 20 years experience of composite machining methodologies,
Technicut has the capability to manufacture optimized tooling solutions
which profile, 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
finishing tools for a diverse array of materials and machining applications
ranging from titanium blisks, blades and impellers to titanium and aluminum
monolithic solid aerostructures.
Titanium cutting
High-speed cutting
10 | 11

Automated Assembly, Systems
Integration and Testing
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 manufacturing.
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 aerospace
manufacturers. MAG Cincinnati Automation offerings include material
handling, composite forming, robots and fixturing solutions employing
standard, flexible or customized solutions to satisfy specific manufacturing
challenges and ergonomic needs.
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)
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.
More Process Experience from MAG Cincinnati Automation
1
, 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
Conveyance
2
End of arm tooling (EOAT)
3
Forming press

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
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, Profilers, 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.
For information regarding local
addresses and partners visit
www.mag-ias.com
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.
Going straight to the top with MAG
– that’s the opportunity offered by
the technology leading companies
in our group.
Through our commitment and innovative
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.
The machines shown are examples. Actual machines may vary based on selected options.