Abstract: An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.

Abstract: A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.

Abstract: An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.

Abstract: A system and method for fabricating large composite fuselages or other vehicle structures, in which the composite structure is fabricated and cured as on a tool, segmented and removed from the tool without disassembling the tool, and then reassembled off the tool to reform the large structure. The tool includes mandrel segments attached to a substructure. The attachments may be moveable to accommodate differential expansion and contraction during curing, and the tool may be rotatable to facilitate access. A composite material of resin and synthetic fibers is applied over the mandrel segments to fabricate the structure on the tool. Caul plates are secured over the composite material, and the composite material is cured on the tool. The resulting structure is cut into part segments which are then removed from the tool, and the part segments are joined to reassemble the large composite structure off the tool.

Abstract: An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.

Abstract: A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.

Abstract: An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.

Abstract: A system and method for splicing multiple plies of material together during the construction of a stringer sheet. A first ply layer is laid onto a portion of a surface of a tool having a contour which defines a stringer, and the first ply layer is pressed down such that an edge of the first ply layer is located on the contour. A second ply layer is laid onto an adjacent portion of the surface, and the second ply layer is pressed down such that the edge of the second ply layer is located on the contour and overlaps the edge of the first ply layer. This process may be repeated for additional ply layers. The system may include an end-effector having a dispenser of the plies of material and a roller for pressing the plies, and a movement mechanism for moving the end-effector over the tool.

Abstract: A system and method for fabricating large composite fuselages or other vehicle structures, in which the composite structure is fabricated and cured as on a tool, segmented and removed from the tool without disassembling the tool, and then reassembled off the tool to reform the large structure. The tool includes mandrel segments attached to a substructure. The attachments may be moveable to accommodate differential expansion and contraction during curing, and the tool may be rotatable to facilitate access. A composite material of resin and synthetic fibers is applied over the mandrel segments to fabricate the structure on the tool. Caul plates are secured over the composite material, and the composite material is cured on the tool. The resulting structure is cut into part segments which are then removed from the tool, and the part segments are joined to reassemble the large composite structure off the tool.

Abstract: An aircraft panel assembly including a panel, a number of open-ended composite stringers, and a number of stringer end caps. Each stringer end cap covers an open end of one of the stringers and includes a base, a vertically extending wall, and an overlap section. The base is bonded to the panel near the open end of the stringer. The vertically extending wall is angled upward from the base and includes an upper periphery. The overlap section extends horizontally from the upper periphery and is bonded to the stringer near the open end of the stringer.

Abstract: A system and method for splicing multiple plies of material together during the construction of a stringer sheet. A first ply layer is laid onto a portion of a surface of a tool having a contour which defines a stringer, and the first ply layer is pressed down such that an edge of the first ply layer is located on the contour. A second ply layer is laid onto an adjacent portion of the surface, and the second ply layer is pressed down such that the edge of the second ply layer is located on the contour and overlaps the edge of the first ply layer. This process may be repeated for additional ply layers. The system may include an end-effector having a dispenser of the plies of material and a roller for pressing the plies, and a movement mechanism for moving the end-effector over the tool.

Abstract: A panel structure, for an aircraft fuselage or wing, including a skin component and a stringer sheet component which are independently constructed and then subsequently integrated to form the panel structure. The skin is constructed and consolidated in a first process, and the stringer sheet is constructed and consolidated in a second process which is independent of the first process. Because the skin and stringer sheet are independently constructed, they may, with less compromise, be constructed with the same or different materials, using the same or different techniques, and at the same or different times to optimize each component. The stringers form cavities, and the cavities may be unfilled or filled with material. The skin and stringer sheet are bonded together in a third process, which is independent of the first and second processes. A frame component may be attached to the panel structure in a fourth process.

Abstract: A cure tool assembly and method of manufacturing a composite part. The cure tool assembly may include a rigid cure tool having a cutter groove and a securing groove formed therein. The cutter groove may be spaced apart from and formed around the cutter groove. The securing groove may be slanted inward, away from a peripheral edge of the rigid cure tool. The cure tool assembly may also include a first sacrificial material located in the cutter groove and a second sacrificial material located in the securing groove. Composite material placed onto the outer surface of the rigid cure tool may bond with the second sacrificial material during cure, creating a desired hold-down force to keep the composite material in place. The resulting cured part may be cut along the cutter groove, thus cutting through the composite material and into the first sacrificial material.

Abstract: A cure tool assembly and method of manufacturing a composite part. The cure tool assembly may include a rigid cure tool having a cutter groove and a securing groove formed therein. The cutter groove may be spaced apart from and formed around the cutter groove. The securing groove may be slanted inward, away from a peripheral edge of the rigid cure tool. The cure tool assembly may also include a first sacrificial material located in the cutter groove and a second sacrificial material located in the securing groove. Composite material placed onto the outer surface of the rigid cure tool may bond with the second sacrificial material during cure, creating a desired hold-down force to keep the composite material in place. The resulting cured part may be cut along the cutter groove, thus cutting through the composite material and into the first sacrificial material.

Abstract: A manufacturing method is adapted for materials that are susceptible to deformation during the manufacturing process, such as composite parts that change shape during curing. The method includes modifying a part design to compensate for changes in the shape of the part that occur during a curing phase of the manufacturing process. A manufacturing mold is created according to the modified part design, then a part is formed in the mold and cured in the mold. While the part is still in the mold after the curing phase, the part is finished according to the modified part design wherein excess material is removed and apertures are created. While the part is still in the mold after the finishing phase, the finished part is inspected using automated inspection equipment to confirm that the finished part conforms to the modified part design.