Abstract: A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a lighting control device onboard the aircraft, activation of a particular exterior light of the aircraft based on the flight plan such that the particular exterior light activates or deactivates when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular exterior light using the particular sensor. The method also includes determining a functionality metric associated with the particular exterior light based on the sensing operation.

Abstract: Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Abstract: Systems and methods for tracking the location of a non-destructive inspection (NDI) scanner using scan data converted into images of a target object. Scan images are formed by aggregating successive scan strips acquired using one or two one-dimensional sensor arrays. An image processor computes a change in location of the NDI scanner relative to a previous location based on the respective positions of common features in partially overlapping scan images. The performance of the NDI scanner tracking system is enhanced by: (1) using depth and intensity filtering of the scan image data to differentiate features for improved landmark identification during real-time motion control; and (2) applying a loop-closure technique using scan image data to correct for drift in computed location. The enhancements are used to improve localization, which enables better motion control and coordinate accuracy for NDI scan data.

Abstract: An aerial vehicle includes a wing body, a first wingtip, a second wingtip, a first edge, and a second edge. The aerial vehicle includes a pair of coaxial rotors configured to rotate in opposite rotational directions about a vehicle axis and a drive assembly configured to rotate the coaxial rotors. A controller is configured to selectively control thrust produced by the coaxial rotors. Selective control of the thrust produced by the coaxial rotors induces a pitch motion of the aerial vehicle to transition between a horizontal flight state and a vertical flight state. In the horizontal flight state, a collective thrust from the coaxial rotors is directed forward. In the vertical flight state, the collective thrust from the coaxial rotors is directed upward.

Abstract: End effectors and systems may capture, release, and/or create a mating engagement between the end effector and a target object. Said end effectors are tolerant of positional and rotational misalignment of the target object, and include a plurality of roller wheels, one or more of which is arranged in a non-parallel plane with respect to one or more other roller wheels. A first roller wheel configured to rotate in a first plane, a second roller wheel configured to rotate in a second plane, and a third roller wheel configured to rotate in a third plane may be arranged such that the end effector is configured to engage a passive receptacle of the target object, to capture the target object. Rotating the roller wheels in the opposite direction may cause the target object to be released or launched, by urging the passive receptacle off of or away from the roller wheels.

Abstract: Methods and apparatus for performing repair operations using an unmanned aerial vehicle. The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. In accordance with various embodiments disclosed below, the unmanned aerial vehicle may be equipped with an easily attachable/removable module that includes an additive repair tool. The additive repair tool is configured to add material to a body of material. For example, the additive repair tool may be configured to apply a sealant or other coating material in liquid form to a damage site on a surface of a structure or object (e.g., by spraying liquid or launching liquid-filled capsules onto the surface). In alternative embodiments, the additive repair tool is configured to adhere a tape to the damage site.

Abstract: Ergonomics improvement systems having wearable sensors and related methods. An example ergonomics improvement system includes an encoder system to couple to a limb of a body. The encoder sensor system to generate first outputs in response to movement of the limb relative to the body to determine a position of the limb relative to the body. The system includes a load sensor to generate a second output representative of a load carried by the body and a position sensor to generate a third output representative of a position of a right foot of the body relative to a position of a left foot of the body.

Abstract: Embodiments described herein utilize Non-Destructive Inspection (NDI) scan data obtained during a process performed on a surface of a structure to update a location of an NDI scanner on the surface. A subsurface feature within the structure is detected based on the NDI scan data, which are correlated with pre-defined position data for the subsurface feature. A measured location of the NDI scanner on the surface is corrected based on the pre-defined position data for the subsurface feature.

Abstract: Methods and apparatus for performing repair operations using an unmanned aerial vehicle. The methods are enabled by equipping the UAV with tools for rapidly repairing a large structure or object (e.g., an aircraft or a wind turbine blade) that is not easily accessible to maintenance personnel. In accordance with various embodiments disclosed below, the unmanned aerial vehicle may be equipped with an easily attachable/removable module that includes an additive repair tool. The additive repair tool is configured to add material to a body of material. For example, the additive repair tool may be configured to apply a sealant or other coating material in liquid form to a damage site on a surface of a structure or object (e.g., by spraying liquid or launching liquid-filled capsules onto the surface). In alternative embodiments, the additive repair tool is configured to adhere a tape to the damage site.

Abstract: A method of curing a composite part, including placing an uncured composite part on a mandrel, placing a plurality of expandable pellets on the uncured composite part, expanding the plurality of expandable pellets, applying a positive pressure to the uncured composite part, and curing the uncured composite part.

Abstract: An example method of joining a first structure and a second structure is described that includes placing an adhesive within a bond cavity for bonding a first structure to a second structure, securing a vacuum bag to the first structure and the second structure so as to surround a portion of the first structure and the second structure, evacuating the bond cavity via a vacuum port to deaerate the adhesive within the bond cavity, after deaerating the adhesive, moving the first structure and the second structure relative to one another such that deaerated adhesive is disposed between the first structure and the second structure, and curing, via one or more heaters, the deaerated adhesive disposed between the first structure and the second structure to bond the first structure to the second structure.

Abstract: A laminated metallic structure includes preformed metallic sheets of graduated three-dimensional sizes. The preformed metallic sheets have a three-dimensional shape and are nested together to form a preform. The preformed metallic sheets in the preform are bonded together to form a three-dimensional body, having a near-net three-dimensional shape.

Abstract: Methods and apparatus for UAV-enabled marking of surfaces during manufacture, inspection, or repair of limited-access structures and objects. A UAV is equipped with a marking module that is configured to apply marking patterns (e.g., alignment features) of known dimensions to surfaces. The marking module may include a 2-D plotter that enables free-form drawing capability. The marking process may involve depositing material on the surface. The marking material may be either permanent or removable. A “clean-up” module may be attached to the UAV platform instead of the marking module, and may include solvents and oscillating or vibrating pads to remove the marks via scrubbing. The clean-up module can also be used for initial surface preparation.

Abstract: A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a lighting control device onboard the aircraft, activation of a particular exterior light of the aircraft based on the flight plan such that the particular exterior light activates or deactivates when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular exterior light using the particular sensor. The method also includes determining a functionality metric associated with the particular exterior light based on the sensing operation.

Abstract: An attachment unit is configured to secure to an object, such as cargo. The attachment unit includes one or more portions that are configured to secure to the object. The one or more portions are further configured to one or both of mechanically or magnetically removably couple to a clasp assembly.

Abstract: An example method of joining a first structure and a second structure is described that includes placing an adhesive within a bond cavity for bonding a first structure to a second structure, securing a vacuum bag to the first structure and the second structure so as to surround a portion of the first structure and the second structure, evacuating the bond cavity via a vacuum port to deaerate the adhesive within the bond cavity, after deaerating the adhesive, moving the first structure and the second structure relative to one another such that deaerated adhesive is disposed between the first structure and the second structure, and curing, via one or more heaters, the deaerated adhesive disposed between the first structure and the second structure to bond the first structure to the second structure.

Abstract: A system for curing a composite part, includes a mandrel configured to receive and support the uncured composite part; a plurality of expandable pellets disposed on the uncured composite part; and a mold configured to hold the mandrel, the uncured composite part, and the plurality of expandable pellets, wherein the plurality of expandable pellets are configured to expand and apply a positive pressure to the uncured composite part according to a change in condition or triggering event, and wherein each of the plurality of expandable pellets includes a blowing agent, a polymer matrix configured to hold the blowing agent, and a flexible skin configured to encapsulate the polymer matrix and the blowing agent, wherein the flexible skin is at least partially permeable with respect to the blowing agent or a gas released by the blowing agent.

Abstract: An example method of joining a first structure and a second structure is described that includes forming a bond cavity between a first structure and a second structure, placing a semi-permeable breather material at one or more exits of the bond cavity, placing a vacuum bag around the bond cavity and the semi-permeable breather material, evacuating the bond cavity via a vacuum port and forcing adhesive into the bond cavity via an adhesive port while the bond cavity is evacuated, and curing the adhesive via one or more heaters to bond the first structure to the second structure.

Abstract: A metamaterial-based substrate (meta-substrate) for piezoelectric energy harvesters. The design of the meta-substrate combines kirigami and auxetic topologies to create a high-performance platform including preferable mechanical properties of both metamaterial morphable structures. The creative design of the meta-substrate can improve strain-induced vibration applications in structural health monitoring, internet-of-things systems, micro-electromechanical systems, wireless sensor networks, vibration energy harvesters, and other applications whose efficiency is dependent on their deformation performance. The meta-substrate energy harvesting device includes a meta-material substrate comprising an auxetic frame having two kirigami cuts and a piezoelectric element adhered to the auxetic frame by means of a thin layer of elastic glue.

Abstract: Methods and apparatus for UAV-enabled marking of surfaces during manufacture, inspection, or repair of limited-access structures and objects. A UAV is equipped with a marking module that is configured to apply marking patterns (e.g., alignment features) of known dimensions to surfaces. The marking module may include a 2-D plotter that enables free-form drawing capability. The marking process may involve depositing material on the surface. The marking material may be either permanent or removable. A “clean-up” module may be attached to the UAV platform instead of the marking module, and may include solvents and oscillating or vibrating pads to remove the marks via scrubbing. The clean-up module can also be used for initial surface preparation.