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A composite part program generator includes a computer-aided design (CAD) system interface, a path generator, a course head manager, a post-processor and a machine simulator. The composite part program generator produces composite part programs for use on a multihead composite material application m

A composite part program generator includes a computer-aided design (CAD) system interface, a path generator, a course head manager, a post-processor and a machine simulator. The composite part program generator produces composite part programs for use on a multihead composite material application machine, such as a composite tape lamination machine or an automated fiber placement (AFP) machine, to manufacture a complex composite parts, including relatively flat, contoured, or generally cylindrical composite parts. This programming method can reduce the labor and time required to produce a composite part program for a multihead composite material application machine by an order of magnitude with respect to manual or existing automated programming methods.

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What is claimed is: 1. A computer-implemented method of programming a multihead composite material application machine, comprising: receiving a composite part definition for a composite part; selecting a reference coordinate system based on the part definition and generating a plurality of paths co

What is claimed is: 1. A computer-implemented method of programming a multihead composite material application machine, comprising: receiving a composite part definition for a composite part; selecting a reference coordinate system based on the part definition and generating a plurality of paths configured to locate a plurality of segments of a composite material to form the part; associating a plurality of associated paths from among the paths to a tool carriage pass; and assigning each of the associated paths to one of a plurality of composite material application heads on the multihead composite material application machine. 2. The computer-implemented method of claim 1, further comprising converting the part definition from a computer-aided design format to a manufacturing tool surface definition and a plurality of ply definitions, wherein the part definition is received in the computer-aided design format. 3. The computer-implemented method of claim 2, further comprising delimiting a composite tape course definition based on the manufacturing tool surface definition, one of the ply definitions and one of the paths. 4. The computer-implemented method of claim 1, further comprising: analyzing each of the paths to determine if any of the paths requires a specialized composite material application head; and assigning any of the paths that requires the specialized composite material application head to a corresponding specialized composite material application head on the multihead composite material application machine. assigning any of the paths that requires the specialized composite material application head to a corresponding specialized composite material application head on the multihead composite material application machine. 5. The computer-implemented method of claim 1, further comprising performing machine-specific optimization to determine the most efficient associations and assignments of the paths. 6. The computer-implemented method of claim 1, further comprising resolving a composite material application head constellation configuration based on a ply orientation and a tool carriage direction of travel. 7. The computer-implemented method of claim 6, further comprising defining a constellation pathway based on the constellation configuration and the associated paths. 8. The computer-implemented method of claim 7, further comprising: delineating a tool carriage route based on the constellation pathway; and delineating a manufacturing tool route based the constellation pathway, wherein the tool carriage route and the manufacturing tool route are interdependent. 9. The computer-implemented method of claim 1, further comprising computing a plurality of machine axis position solutions to control at least one selected from the following: the tool carriage, the manufacturing tool and the composite material application heads; wherein the machine axis position solutions are based at least in part on one selected from the following: the tool carriage route, the manufacturing tool route, the constellation configuration, the paths, the association of the paths, and the assignment of the paths. 10. The computer-implemented method of claim 9, further comprising writing a computer numerical control output data file based on the machine axis position solutions. 11. The computer-implemented method of claim 9, further comprising writing an output data file based on the machine axis position solutions, wherein the output data file is compatible with a simulator. 12. The computer-implemented method of claim 1, further comprising simulating the multihead composite material application machine, a machine controller, and a manufacturing tool to verify collision avoidance and to facilitate manual process refinement. 13. The computer-implemented method of claim 1, wherein the multihead composite material application machine comprises a plurality of composite tape laying heads. 14. The computer-implemented method of claim 1, wherein the multihead composite material application machine comprises a plurality of composite fiber placement heads. 15. The computer-implemented method of claim 1, further comprising adjusting a motion profile of one of the application heads in response to dynamically occurring data. 16. A computer program product for programming a multihead composite material application machine, including a computer-readable medium encoded with instructions configured to be executed by a processor in order to perform predetermined operations comprising: receiving a composite part definition for a composite part; selecting a reference coordinate system based on the part definition and generating a plurality of paths configured to locate a plurality of segments of a composite material to form the part; associating a plurality of associated paths from among the paths to a tool carriage pass; and assigning each of the associated paths to one of a plurality of composite material application heads on the multihead composite material application machine. 17. The computer program product of claim 16, wherein the predetermined operations further comprise converting the part definition from a computer-aided design format to a manufacturing tool surface definition and a plurality of ply definitions, wherein the part definition is received in the computer-aided design format. 18. The computer program product of claim 17, wherein the predetermined operations further comprise delimiting a composite tape course definition based on the manufacturing tool surface definition, one of the ply definitions and one of the paths. 19. The computer program product of claim 16, wherein the predetermined operations further comprise: analyzing each of the paths to determine if any of the paths requires a specialized composite material application head; and assigning any of the paths that requires the specialized composite material application head to a corresponding specialized composite material application head on the multihead composite material application machine. 20. The computer program product of claim 16, wherein the predetermined operations further comprise performing machine-specific optimization to determine the most efficient associations and assignments of the paths. 21. The computer program product of claim 16, wherein the predetermined operations further comprise resolving a composite material application head constellation configuration based on a ply orientation and a tool carriage direction of travel. 22. The computer program product of claim 21, wherein the predetermined operations further comprise defining a constellation pathway based on the constellation configuration and the associated paths. 23. The computer program product of claim 22, wherein the predetermined operations further comprise: delineating a tool carriage route based on the constellation pathway; and delineating a manufacturing tool route based the constellation pathway, wherein the tool carriage route and the manufacturing tool route are interdependent. 24. The computer program product of claim 16, wherein the predetermined operations further comprise computing a plurality of machine axis position solutions to control at least one selected from the following: the tool carriage, the manufacturing tool and the composite material application heads; wherein the machine axis position solutions are based at least in part on one selected from the following: the tool carriage route, the manufacturing tool route, the constellation configuration, the paths, the association of the paths, and the assignment of the paths. 25. The computer program product of claim 24, wherein the predetermined operations further comprise writing a computer numerical control output data file based on the machine axis position solutions. 26. The computer program product of claim 24, wherein the predetermined operations further comprise writing an output data file based on the machine axis position solutions, wherein the output data file is compatible with a simulator. 27. The computer program product of claim 16, wherein the predetermined operations further comprise simulating the multihead composite material application machine, a machine controller, and a manufacturing tool to verify collision avoidance and to facilitate manual process refinement. 28. The computer program product of claim 16, wherein the multihead composite material application machine comprises a plurality of composite tape laying heads. 29. The computer program product of claim 16, wherein the multihead composite material application machine comprises a plurality of composite fiber placement heads. 30. The computer program product of claim 16, wherein the predetermined operations further comprise adjusting a motion profile of one of the application heads in response to dynamically occurring data. 31. A composite part program generator stored on a computer readable medium for programming a multihead composite material application machine, comprising: a computer-aided design interface configured to receive a composite part definition for a composite part; a path generator configured to select a reference coordinate system based on the part definition to generate a plurality of paths configured to locate a plurality of segments of a composite material to form the part; a course head manager configured to associate a plurality of associated paths from among the paths to a tool carriage pass, and assign each of the associated paths to one of a plurality of composite material application heads on the multihead composite material application machine. 32. The composite part program generator of claim 31, wherein the computer-aided design interface is further configured to convert the part definition from a computer-aided design format to a manufacturing tool surface definition and a plurality of ply definitions, wherein the part definition is received in the computer-aided design format. 33. The composite part program generator of claim 32, wherein the path generator is further configured to delimit a composite tape course definition based on the manufacturing tool surface definition, one of the ply definitions and one of the paths. 34. The composite part program generator of claim 31, wherein the course head manager is further configured to analyze each of the paths to determine if any of the paths requires a specialized composite material application head and assign any of the paths that requires the specialized composite material application head to a corresponding specialized composite material application head on the multihead composite material application machine. 35. The composite part program generator of claim 31, wherein the course head manager is further configured to perform machine-specific optimization to determine the most efficient associations and assignments of the paths. 36. The composite part program generator of claim 31, wherein the course head manager is further configured to resolve a composite material application head constellation configuration based on a ply orientation and a tool carriage direction of travel. 37. The composite part program generator of claim 36, further comprising a post-processor configured to define a constellation pathway based on the constellation configuration and the associated paths. 38. The composite part program generator of claim 37, wherein the post-processor is further configured to delineate a tool carriage route and a manufacturing tool route based the constellation pathway, wherein the tool carriage route and the manufacturing tool route are interdependent. 39. The composite part program generator of claim 37 wherein the post-processor is further configured to compute a plurality of machine axis position solutions to control at least one selected from the following: the tool carriage, the manufacturing tool and the composite material application heads; wherein the machine axis position solutions are based at least in part on one selected from the following: the tool carriage route, the manufacturing tool route, the constellation configuration, the paths, the association of the paths, and the assignment of the paths. 40. The composite part program generator of claim 39, wherein the post-processor is further configured to write a computer numerical control output data file based on the machine axis position solutions. 41. The composite part program generator of claim 35, wherein wherein the post-processor is further configured to write an output data file based on the machine axis position solutions, wherein the output data file is compatible with a simulator. 42. The composite part program generator of claim 31, further comprising a machine simulator configured to simulate the multihead composite material application machine, a machine controller, and a manufacturing tool to verify collision avoidance and to facilitate manual process refinement. 43. The composite part program generator of claim 31, wherein the multihead composite material application machine comprises a plurality of composite tape laying heads. 44. The composite part program generator of claim 31, wherein the multihead composite material application machine comprises a plurality of composite fiber placement heads. 45. The composite part program generator of claim 31, further comprising a post-processor configured to adjust a motion profile of one of the application heads in response to dynamically occurring data.