Composites, Fiberglass & Advanced Materials worked example

Fiber Ply Count at 99% layup cell uptime: a worked example

This scenario runs the fiber ply count calculation on the strong side: 99% layup cell uptime, with every other input held at its documented default. checking ply capacity for a laminate schedule or kit plan

The inputs for this scenario

  • Plies laid up per layup cycle: 18 plies / cycle (unchanged)
  • Scheduled layup cycles in the run: 40 cycles (unchanged)
  • Layup cell uptime: 99 % (raised for this scenario; the documented default is 90)
  • Ply first-pass acceptance yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross fiber ply count = plies completed per cycle × planned ply processing cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 691 plies for good fiber ply count, the number this scenario is built around.
  • At this operating point the engine returns 720 plies for gross fiber ply count.
  • At this operating point the engine returns 7.2 plies for fiber ply count lost to downtime.
  • At this operating point the engine returns 21.38 plies for fiber ply count lost to scrap or rework.

How this compares with the baseline

  • Against the tool's baseline example, where layup cell uptime sits at 90% and the headline result is 629 plies, this scenario comes in 10% above the baseline at 691 plies.
  • Use it when planning a layup run, sizing a kit order, or quoting capacity for a panel/spar program where ply count drives cure time and labor hours. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • good fiber ply count: 691 plies (headline result)
  • gross fiber ply count: 720 plies
  • fiber ply count lost to downtime: 7.2 plies
  • fiber ply count lost to scrap or rework: 21.38 plies

Run it with your numbers

  • Every input above is editable in the live Fiber Ply Count calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.