Abstract: Systems and methods are provided for demolding a composite part from a mandrel. The method includes mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has been hardened onto a mandrel, mechanically coupling a second arm of an extraction tool to a second arcuate portion of the composite part, and separating the composite part from the mandrel by iteratively performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm, and elastically straining the second arcuate portion of the composite part via the second arm.

Abstract: Systems are provided for fabricating a preform for a fuselage section of an aircraft. The system includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

Abstract: Systems and methods are provided for placing preforms onto a mandrel. One illustrative method includes moving a mandrel in a process direction relative to a station(s) that comprises multiple pick-and-place machine(s), identifying a tray that stores a preform comprising an unhardened fiber-reinforced material, placing the strong back at the preform via at least one of the pick-and-place machine(s), applying a vacuum to hold the preform in contact with the strong back, transporting the preform to a mandrel via the pick-and-place machine(s), and placing the preform onto the mandrel.

Abstract: Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.

Abstract: A lamination head for laying up a composite laminate includes a material supply drum supporting roll of layup material backed by a backing layer, a first and second separation device respectively having a first and second horn, and a first and second compaction device. When the first separation device is extended, the first horn is in close proximity to the first compaction device, causing a layup material to separate from the backing layer and move underneath the first compaction device as the lamination head moves along a first direction of travel. When the second separation device is extended, the second horn is in close proximity to the second compaction device, causing the layup material to separate from the backing layer and move underneath the second compaction device as the lamination head moves along a second direction of travel opposite the first direction of travel.

Abstract: Systems and methods are provided for inspecting a wing panel. Some methods include advancing a wing panel through a Non-Destructive Inspection (NDI) station, and inspecting the wing panel with inspection heads at the NDI station. The wing panel may be suspended beneath a strongback during inspection and/or advancement, such as by using vacuum couplers and/or adjustable-length pogos of the strongback, and suspending may include enforcing a contour to the wing panel using the vacuum couplers and/or pogos. Other methods include receiving a wing panel at an NDI station and inspecting a portion thereof during movement through the NDI station. Some systems include a track, a strongback to suspend a wing panel beneath it and to advance along the track, and an NDI station disposed at the track to inspect the wing panel while suspended.

Abstract: Systems and methods are provided for processing composite parts. One embodiment is a method for preparing a composite part for assembly. The method includes receiving a mandrel to which a composite part has been molded, and operating a work station to install an indexing feature into a manufacturing excess of the composite part.

Abstract: Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

Abstract: A tubular material application system for applying a tubular material onto an elongate mandrel includes a gripper system including a first gripper and a second gripper configured to move with inchworm-type movement along an elongated mandrel and incrementally apply a tubular material onto the mandrel to thereby result in a tubular material-mandrel assembly.

Abstract: A lamination head for laying up a composite laminate includes a material supply drum supporting roll of layup material backed by a backing layer, a first and second separation device respectively having a first and second horn, and a first and second compaction device. When the first separation device is extended, the first horn is in close proximity to the first compaction device, causing a layup material to separate from the backing layer and move underneath the first compaction device as the lamination head moves along a first direction of travel. When the second separation device is extended, the second horn is in close proximity to the second compaction device, causing the layup material to separate from the backing layer and move underneath the second compaction device as the lamination head moves along a second direction of travel opposite the first direction of travel.

Abstract: A self-threading lamination head has a material supply drum, a backing layer collection drum, and a material threading system. The material supply drum supports a material roll of layup material backed by a backing layer. The material threading system includes at least one threading belt located on one side of the lamination head. The threading belt is supported by belt rollers driven by a belt drive motor. A belt-mounted layer engagement device is coupled to the threading belt for engaging a backing layer leading edge portion. The backing layer collection drum collects the backing layer as the lamination head applies the layup material onto a substrate. The belt drive motor drives the threading belt over the belt rollers and causes the belt-mounted layer engagement device to thread the backing layer through the lamination head, and position the backing layer leading edge portion proximate the backing layer collection drum.

Abstract: An ergonomic frame-filler placement tool is manually operable to supply a vacuum fluid flow at a distal end of the tool that can be used by a worker to pick up and hold a piece of frame-filler material to the distal end of the tool, which enables the worker to manipulate the tool to position the piece of frame-filler material over a desired location of a fuselage mandrel and then manually stop the vacuum fluid flow at the distal end of the tool to position the piece of frame-filler material at the desired location on the mandrel.

Abstract: An example method for simultaneously manufacturing a plurality of objects is described. The method includes simultaneously cycling a plurality of pallets through a conveyor system. The conveyor system is cyclical, and the conveyor system includes an entrance point for each pallet, an exit point, and a plurality of manufacturing points corresponding to a plurality of manufacturing devices. Simultaneously cycling the plurality of pallets includes simultaneously cycling the plurality of pallets past the plurality of manufacturing points for two or more cycles, wherein each pallet is associated with a set of manufacturing instructions for a corresponding object. The method further includes, while simultaneously cycling the plurality of pallets through the conveyor system, using a different combination of the plurality of manufacturing devices to manufacture each object in accordance with the set of manufacturing instructions associated with each pallet, thereby manufacturing different objects for each pallet.

Abstract: Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

Abstract: Systems and methods are provided for demolding a composite part from a mandrel. The method includes mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has been hardened onto a mandrel, mechanically coupling a second arm of an extraction tool to a second arcuate portion of the composite part, and separating the composite part from the mandrel by iteratively performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm, and elastically straining the second arcuate portion of the composite part via the second arm.

Abstract: Systems and methods are provided for fabricating a part on a mandrel. The system includes a series of stations divided into at least two groups of stations, wherein each group of stations performs fabrication operations on a particular zone of the mandrel.

Abstract: Systems and methods are provided for inspecting a structure. One embodiment is a method for inspecting a structure. The method includes advancing a structure along a track in a process direction, aligning a Non-Destructive Inspection (NDI) station at the track with an edge of the structure that was trimmed upstream of the cleaning station, imaging the edge via the Non-Destructive Inspection (NDI) station, characterizing the edge based on the imaging, and advancing the structure further in the process direction via the track.

Abstract: Systems and methods are provided for inspecting aircraft fuselages. Non-Destructive Inspection (NDI) stations inspect sections of a fuselage via pulsed-line assembly techniques. After each pulse, a section of fuselage is moved by less than its length, and one or more NDI stations disposed at different portions of the section to inspect the section of fuselage for out-of-tolerance conditions. A method for inspecting a structure for inconsistencies which includes advancing a structure along a track in a process direction through a Non-Destructive Inspection (NDI) station, indexing the structure to the NDI station and inspecting the structure with the NDI station.

Abstract: Systems and methods are provided for assembling an aircraft. The method includes receiving a lower half barrel section of fuselage that is inverted to a keel-up orientation; and installing a floor grid into the lower half barrel section while inverted.

Abstract: Systems and methods are provided for processing composite parts. One embodiment is a method for preparing a composite part for assembly. The method includes receiving a mandrel to which a composite part has been molded, and operating a work station to install an indexing feature into a manufacturing excess of the composite part.