This work presents an automated fabric layup solution based on a new method to deform fiberglass fabric, referred to as shifting, for the layup of noncrimp fabric (NCF) plies. The shifting method is intended for fabric with tows only in 0 deg (warp) and 90 deg (weft) directions, where the fabric is sequentially constrained and then rotated through a deformation angle to approximate curvature. Shifting is conducted in a two-dimensional (2D) plane, making the process easy to control and automate, but can be applied for fabric placement in three-dimensional (3D) models, either directly or after a ply kitting process and then manually placed. Preliminary tests have been conducted to evaluate the physical plausibility of the shifting method. Layup tests show that shifting can deposit fabric accurately and repeatedly while avoiding out-of-plane deformation.

This thesis presents a new fabric deformation method, referred to as shifting, for the layup of noncrimp fabric (NCF) plies with the intent of creating an automated layup solution. The mathematical model for the new method has been presented to describe the method and provide the ground work for future path planning of an automation solution. Testing has been completed to show that shifting can produce layups with 2 dimensional geometry without generating out-of-plane distortion. Fatigue tensile testing was conducted in order to understand the effect of the shifting method on the