Abstract: A web (102) of backing material to which a web (104) of composite material is adhered is tensioned between two reels (12). A mold (100) is brought into position relative to the webs (102, 104) and located in an oriented closely spaced position relative to a ply (106) cut from the web (104). Localized downward forces are applied to the backing material (102) opposite the ply (106) by extending vacuum cups (40) or ejecting streams of air from nozzles (72). The downward forces move the ply (106) toward the mold (100) and into contact with portions of the mold (100). The ply (106) adheres to the portions of the mold (100) which it contacts. The vacuum cups (40) are moved along the web (102) and then retracted. The suction of the vacuum cups (40) and the tensioning of the web (102) cause separation of the web (102) from the adhered ply (106). When streams of air provide the downward force, the tensioning of the web (102) causes the separation.

Abstract: A ply (100) of fiber reinforced composite material is laid onto a mandrel (30) having a vacuum ported upper surface with a generally U-shaped cross section. Ply (100) is laid onto the top web (32) of mandrel (30), with its side edges being laid in a cantilevered fashion. A flexible bag (20) is inflated into a stretched condition and lowered over mandrel (30). Bag (20) rolls over mandrel (30) to form play (100) down over mandrel (30). As bag (20) rolls over mandrel (30), it folds ply (100) along two contoured bend lines between the web (32) and flanges (34, 36) of mandrel (30) and simultaneously restrains ply (100) from folding along a straight line. Bag (20) engages a seal (38) carried by mandrel (30). A vacuum is applied through mandrel (30) to evacuate the area between bag (20) and mandrel (30) within seal (38), to compact ply ( 100). Each ply of composite material is formed and compacted before laying another ply.