Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station.

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station.

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

Abstract: A method is provided for fabricating a composite ply layup with a desired shape. The method includes moving a shuttle having a sheet of elastic material into engagement with at least one composite ply at a ply pickup station, and picking up the at least one composite ply with the shuttle. The method also includes transporting the shuttle and the at least one composite ply from the ply pickup station to a forming station, and moving the shuttle and the at least one composite ply into engagement with a forming tool at the forming station or any previously laid plies on the forming tool. The method further includes compacting the at least one composite ply on the forming tool or any previously laid plies on the forming tool with the shuttle to form the composite ply layup with the desired shape.

Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Abstract: A composite part, such as a stiffener is formed in place. A composite charge is placed on a tool spanning a mold cavity, with the centerline of the charge offset from the centerline of the mold cavity. Opposite sides of the charge are held against the tool as the charge is formed into the mold cavity. One side of the charge is held against movement on the tool while the other side of the charge is allowed to slip over the tool toward the mold cavity.

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station. The manufacturing system further includes one or more trimming devices configured to trim the composite laminate.

Abstract: A forming module for forming a composite laminate part over a tool is provided. The forming module comprises a base, a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted, and a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.

Abstract: A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.

Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, ?45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.

Abstract: A method is presented. The method comprises identifying a desired shape of a ply on a tool, in which the ply has a fiber orientation; identifying a cut shape for the ply, in which the cut shape is different than the desired shape; cutting a composite prepreg ply to have the cut shape, the composite prepreg ply having the fiber orientation; using a deformable carrier to apply the composite prepreg ply having the cut shape to the tool such that the composite prepreg ply has the desired shape on the tool.

Abstract: A method of manufacturing curved composite structural elements can include fabricating a web ply in a flat curve over a removable substrate and laying up the ply on a curved web surface of a manufacturing tool. The method also can include laying up a diagonal ply with fibers oriented at +/?45° from the centerline of the web surface. The method further can include cutting a unidirectional composite tape into segments and laying up the tape segments to form a cross ply with a fiber orientation normal to the centerline of the web surface. One or both edges of the diagonal and cross plies may be folded over one or two sides of the manufacturing tool to form one or two flange surfaces. Additionally, a cap ply can be laid up on one or both flange surfaces using composite tape. The structural element layup can then be inspected and any excess composite material can be trimmed away.

Abstract: A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.

Abstract: A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.

Abstract: A method is provided of fabricating a composite stiffener having a curved web and at least one curved flange. A substantially straight length of unidirectional prepreg tape is placed on a carrier. The at least one curved flange is formed by using the carrier to steer a first portion of the tape onto a first curved tool surface. The curved web is formed by using the carrier to form a second portion of the tape onto a second curved tool surface.

Abstract: A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.

Abstract: A composite part, such as a stiffener is formed in place. A composite charge is placed on a tool spanning a mold cavity, with the centerline of the charge offset from the centerline of the mold cavity. Opposite sides of the charge are held against the tool as the charge is formed into the mold cavity. One side of the charge is held against movement on the tool while the other side of the charge is allowed to slip over the tool toward the mold cavity.

Abstract: A composite part, such as a stiffener is formed in place. A composite charge is placed on a tool spanning a mold cavity, with the centerline of the charge offset from the centerline of the mold cavity. Opposite sides of the charge are held against the tool as the charge is formed into the mold cavity. One side of the charge is held against movement on the tool while the other side of the charge is allowed to slip over the tool toward the mold cavity.

Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, ?45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.

Abstract: A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.