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 for making a pressure bulkhead assembly of an aircraft includes determining first locations and first orientations of a plurality of first holes, pre-drilled in an aft pressure bulkhead. The method also includes determining a first surface profile of a first interface surface of the aft pressure bulkhead and determining a second surface profile of a second interface surface of each one of a plurality of splice angles. The method also includes determining second locations and second orientations of a plurality of second holes to be drilled in each one of the plurality of splice angles corresponding to the plurality of first holes in the aft pressure bulkhead and drilling the plurality of second holes in each one of the plurality of splice angles at the second locations and second orientations.

Abstract: Systems (100) for assembling stiffened composite structures comprise a layup mandrel (102) and a network (104) of fluid lines (116) configured to be selectively and fluidically coupled to stringer bladders (118) positioned relative to the layup mandrel (102). Bladder vent plugs (300) are adjustable in length andare configured to close stringer bladders (118) except for fluid connection to the fluid lines (116).

Abstract: An apparatus, system, and methods for providing flowable material to a part-forming fixture. The apparatus comprising a tool manifold and a fixture manifold. The tool manifold comprises a tool-manifold base and a plurality of tool fittings extending through the tool-manifold base. The fixture manifold comprises a fixture-manifold base and a plurality of fixture fittings extending through the fixture-manifold base. An interface end of each one of the plurality of tool fittings is removably attachable to an interface end of a corresponding one of the plurality of fixture fittings such that, when attached, a seal is created between the tool fittings and the corresponding fixture fitting and flowable material is flowable from each one of the tool fittings into the corresponding one of the fixture fittings.

Abstract: A membrane assembly for vacuum bagging includes an elongate sheet of flexible material capable of being rolled up into a cylindrical configuration and unrolled from the cylindrical configuration into a flattened-out configuration, a bistable tape spring attached to or captured by the elongate sheet, and an inflatable tube attached to or captured by the elongate sheet. The bistable tape spring has a first stable state which is a straightened-out state, a second stable state which is a rolled-up state, and a transition state between the first and second stable states. The inflatable tube is sealed at one end and has an orifice at the other end for admission of a fluid therethrough for inflation of the inflatable tube.

Abstract: An apparatus for processing a composite structure includes a mandrel that includes a tooling surface and vacuum bagging that includes an elastomeric membrane and a bagging surface. The apparatus also includes a surface interface formed between the mandrel and the elastomeric membrane. The surface interface includes a suction channel formed in at least one of the tooling surface of the mandrel and the bagging surface of the elastomeric membrane. The elastomeric membrane is configured to be sealed to the mandrel along the suction channel in response to a vacuum applied to the suction channel.

Abstract: A method for making a pressure bulkhead assembly of an aircraft includes determining first locations and first orientations of a plurality of first holes, pre-drilled in an aft pressure bulkhead. The method also includes determining a first surface profile of a first interface surface of the aft pressure bulkhead and determining a second surface profile of a second interface surface of each one of a plurality of splice angles. The method also includes determining second locations and second orientations of a plurality of second holes to be drilled in each one of the plurality of splice angles corresponding to the plurality of first holes in the aft pressure bulkhead and drilling the plurality of second holes in each one of the plurality of splice angles at the second locations and second orientations.

Abstract: A part transfer system includes a movable support, a plurality of arms coupled to the movable support, and an end effector coupled to each of the plurality of arms. The end effector includes a body and a plurality of dividers each coupled to the body. The plurality of dividers divides the body into a plurality of partitions. The end effector includes a plurality of vacuum ports each in fluid communication with one of the plurality of partitions. The part transfer system further includes a vacuum source in fluid communication with at least one of the plurality of vacuum ports. Each of the plurality of vacuum ports is configured to draw a fluid from the plurality of partitions to establish a vacuum between the end effector and a part that is engaged with the end effector, thereby securing the part to the end effector.

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 membrane assembly for vacuum bagging includes an elongate sheet of flexible material capable of being rolled up into a cylindrical configuration and unrolled from the cylindrical configuration into a flattened-out configuration, a bistable tape spring attached to or captured by the elongate sheet, and an inflatable tube attached to or captured by the elongate sheet. The bistable tape spring has a first stable state which is a straightened-out state, a second stable state which is a rolled-up state, and a transition state between the first and second stable states. The inflatable tube is sealed at one end and has an orifice at the other end for admission of a fluid therethrough for inflation of the inflatable tube.