Abstract: Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Abstract: A method of cutting an uncured composite material is presented. The uncured composite material is positioned onto a surface of a tool and over a groove in the surface, the groove having a groove filler and magnetic material within the groove. A cutter having a guide is positioned relative to the uncured composite material, the guide configured to detect the magnetic material. The uncured composite material is cut above the groove using the cutter as the cutter moves along a path defined by the groove, the cutter guided by the guide detecting the magnetic material in the groove.

Abstract: A method of cutting an uncured composite material is presented. The uncured composite material is positioned onto a surface of a tool and over a groove in the surface, the groove having a groove filler and magnetic material within the groove. A cutter having a guide is positioned relative to the uncured composite material, the guide configured to detect the magnetic material. The uncured composite material is cut above the groove using the cutter as the cutter moves along a path defined by the groove, the cutter guided by the guide detecting the magnetic material in the groove.

Abstract: A system to adjust extension lengths of slats of a work platform relative to a workpiece includes sensors to collect first data associated with a position of an outer surface of the workpiece at a height of the slats. The system includes actuators configured to extend or retract the slats. The system also includes a controller coupled to the sensors and to the actuators. The controller is configured to receive the first data and second data associated with rotation of the workpiece. The controller is configured to provide signals to the actuators of the work platform based on the first data and the second data. The signals cause the actuators to adjust or maintain extension lengths of the slats of the work platform to maintain separation distances between ends of the slats and the outer surface of the workpiece within a separation distance range as the workpiece rotates.

Abstract: A carrier film set configured to apply a number of stiffener assemblies to a layup mandrel, the carrier film set comprising: a number of alignment features configured to align the carrier film set relative to the layup mandrel; and a number of indexing features configured to index the number of stiffener assemblies onto the carrier film set.

Abstract: Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Abstract: A method of fabricating a composite structure is presented. The method comprises laying up a plurality of composite plies over a layup mandrel; positioning a first caul plate and a second caul plate over the plurality of composite plies, leaving composite material exposed; removing at least part of the composite material exposed between the first caul plate and the second caul plate to separate a first composite section from a second composite section; curing the first composite section and the second composite section to form a first composite part and a second composite part; and removing the first composite part and the second composite part from the layup mandrel immediately following curing.

Abstract: A carrier film set configured to apply a number of stiffener assemblies to a layup mandrel, the carrier film set comprising: a number of alignment features configured to align the carrier film set relative to the layup mandrel; and a number of indexing features configured to index the number of stiffener assemblies onto the carrier film set.

Abstract: A method is presented. A machine head is positioned in a desired location relative to a material on a tool using a sensor connected to the machine head and calibrated to detect magnetic material in the tool. An operation is performed on the material using the machine head starting at the desired location.

Abstract: A method of fabricating a composite structure is presented. The method comprises laying up a plurality of composite plies over a layup mandrel; positioning a first caul plate and a second caul plate over the plurality of composite plies, leaving composite material exposed; removing at least part of the composite material exposed between the first caul plate and the second caul plate to separate a first composite section from a second composite section; curing the first composite section and the second composite section to form a first composite part and a second composite part; and removing the first composite part and the second composite part from the layup mandrel immediately following curing.

Abstract: Systems and methods are provided for dynamically altering the shape of a forming tool for a composite part during forming. An exemplary forming tool includes a main body that holds a first portion of a multi-layer laminate, and a platform that holds a second portion of the laminate aligned with the first portion. The forming tool also includes a biasing device that repositions the second portion with respect to the first portion during forming of the laminate, causing shear stresses between the layers of the laminate.

Abstract: A method is presented. A machine head is positioned in a desired location relative to a material on a tool using a sensor connected to the machine head and calibrated to detect magnetic material in the tool. An operation is performed on the material using the machine head starting at the desired location.

Abstract: Systems and methods are provided for dynamically altering the shape of a forming tool for a composite part during forming. An exemplary forming tool includes a main body that holds a first portion of a multi-layer laminate, and a platform that holds a second portion of the laminate aligned with the first portion. The forming tool also includes a biasing device that repositions the second portion with respect to the first portion during forming of the laminate, causing shear stresses between the layers of the laminate.