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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 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.
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 HyperMach
TM
linear motor profiler is achieving the highest metal
removal rates in production 7538 cm
3
/min. (460 in
3
/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
www. mag- i as. com
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.