Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Abstract: A system for forming composite material parts comprises a charge station, a tool station, a forming station, a cooling station, a pick and place apparatus, and a transfer unit. The charge station may receive a first charge. The tool station may receive a first tool. The forming station may form a second charge against a second tool. The cooling station may cool a third charge and a third tool. The pick and place apparatus may retrieve the first charge from the charge station and the first tool from the tool station and transport both the first charge and the first tool to the forming station. The transfer unit may transport the second charge and the second tool from the forming station to the cooling station while at the same time transporting the third charge and the third tool from the cooling station to the tool station.

Abstract: A translating die apparatus and method for forming a piece of material into a part having complex contours. The translating die apparatus may comprise upper and lower mounts, fixed upper and lower dies fixed to the upper and lower mounts, respectively, and movable upper and lower dies translatably coupled with the mounts and configured to translate laterally toward and away from the fixed upper and lower dies. The piece of material may be placed between the upper and lower dies and one of the mounts may be actuated toward another of the mounts to sandwich the piece of material between the upper and lower dies. Simultaneously, the movable upper and lower dies may translate toward the fixed upper and lower dies, until the movable and fixed dies abut each other when the upper and lower dies are fully pressing the piece of material therebetween.

Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Abstract: A method and part forming apparatus configured for forming an aircraft stringer. The part forming apparatus may comprise a forming tool, a rigid plate, and a hollow bladder. The forming tool may comprise a material trough, a bladder extension trough laterally aligned with and open to the material trough, and a recessed pocket extending from either side of the bladder extension trough and adjacent to the material trough. The method comprises placing composite material into the material trough, placing the bladder onto the composite material and through the bladder extension trough, placing the rigid plate into the recessed pocket and over the bladder, and then placing skin laminate over the bladder and the composite material. Once each of these components is in place, the forming tool may be vacuum bagged and the composite material and skin laminate may be co-cured to form the stringer.

Abstract: A system for forming composite material parts comprises a charge station, a tool station, a forming station, a cooling station, a pick and place apparatus, and a transfer unit. The charge station may receive a first charge. The tool station may receive a first tool. The forming station may form a second charge against a second tool. The cooling station may cool a third charge and a third tool. The pick and place apparatus may retrieve the first charge from the charge station and the first tool from the tool station and transport both the first charge and the first tool to the forming station. The transfer unit may transport the second charge and the second tool from the forming station to the cooling station while at the same time transporting the third charge and the third tool from the cooling station to the tool station.

Abstract: A translating die apparatus and method for forming a piece of material into a part having complex contours. The translating die apparatus may comprise upper and lower mounts, fixed upper and lower dies fixed to the upper and lower mounts, respectively, and movable upper and lower dies translatably coupled with the mounts and configured to translate laterally toward and away from the fixed upper and lower dies. The piece of material may be placed between the upper and lower dies and one of the mounts may be actuated toward another of the mounts to sandwich the piece of material between the upper and lower dies. Simultaneously, the movable upper and lower dies may translate toward the fixed upper and lower dies, until the movable and fixed dies abut each other when the upper and lower dies are fully pressing the piece of material therebetween.

Abstract: A method and part forming apparatus configured for forming an aircraft stringer. The part forming apparatus may comprise a forming tool, a rigid plate, and a hollow bladder. The forming tool may comprise a material trough, a bladder extension trough laterally aligned with and open to the material trough, and a recessed pocket extending from either side of the bladder extension trough and adjacent to the material trough. The method comprises placing composite material into the material trough, placing the bladder onto the composite material and through the bladder extension trough, placing the rigid plate into the recessed pocket and over the bladder, and then placing skin laminate over the bladder and the composite material. Once each of these components is in place, the forming tool may be vacuum bagged and the composite material and skin laminate may be co-cured to form the stringer.

Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: A system (10) is provided for perforating and consolidating an uncured laminate sheet (14) at a substantially low pressure in one cycle of operation. The system (10) includes a pinmat (20) that is coupled to a tool base (24). This pinmat (20) is comprised of a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to displace discontinuous fibers (32) within the laminate sheet (14) so as to perforate the laminate sheet (14). Furthermore, the mat portion (28) has one or more ventilation holes (58) integrally formed therein for allowing gas adjacent to the pins (26) to be withdrawn therefrom so as to improve the consolidation of the laminate sheet (14). The system (10) also includes a positive pressure source (12) that is coupled to the laminate sheet (14) for forcing the laminate sheet (14) onto the pinmat (20).

Abstract: An aircraft composite assembly 10 is provided, including a first composite member 12, at least one first flange joint 26 comprising a first plurality of plies 24 cured to the first composite member 12, a second composite member 30, and at least one second flange joint 38 comprising a second plurality of plies 36 cured to the second composite member 30. The at least one second flange joint 38 is bonded to the at least one first flange joint 26 such that the first composite member 12 is affixed to the second composite member 30.

Abstract: An aircraft composite assembly 10 is provided, including a first composite member 12, at least one first flange joint 26 comprising a first plurality of plies 24 cured to the first composite member 12, a second composite member 30, and at least one second flange joint 38 comprising a second plurality of plies 36 cured to the second composite member 30. The at least one second flange joint 38 is bonded to the at least one first flange joint 26 such that the first composite member 12 is affixed to the second composite member 30.