Abstract: In one embodiment, a computer-implemented method for transforming a CAD model of an object between engineering states includes generating a first reference geometry to represent a first engineering state. A parametric CAD model of the object may be generated to represent the object in the first engineering state by constructing the parametric CAD model as having dependence on the first reference geometry. A second reference geometry may be generated to represent a second engineering state. The parametric CAD model may be regenerated to represent the object in the second engineering state by replacing the first reference geometry with the second reference geometry.

Abstract: In one embodiment, a computer-implemented method for transforming a CAD model of an object between engineering states includes generating a first reference geometry to represent a first engineering state. A parametric CAD model of the object may be generated to represent the object in the first engineering state by constructing the parametric CAD model as having dependence on the first reference geometry. A second reference geometry may be generated to represent a second engineering state. The parametric CAD model may be regenerated to represent the object in the second engineering state by replacing the first reference geometry with the second reference geometry.

Abstract: The present invention is directed to the incorporation of a substructure into tooling for constructing composite structures in order to control thermal expansion of the tooling during aerospace manufacturing processes. Substructure, such as headers and/or gussets is added to the tooling to constrain the growth of the laminate expansion and/or control the diametric growth of the tool during the curing cycle. The thickness of the face-sheet of the tooling also may be reduced in order to further reduce the effective coefficient of thermal expansion (CTE) of the tooling.

Abstract: The present invention provides an automated mandrel clamping and indexing mechanism for a multi-piece AFP mandrel wherein a clamping mechanism is used in order to secure mandrel segments together as well as to join mandrel segments to end rings. The clamping mechanism is preferably integrated with an indexing mechanism according to embodiments of the present invention such that mandrel segments will preferably remain securely connected and aligned until air is applied to the clamping and indexing mechanism in order to unclamp the secured mandrel segments and remove the part being manufactured. The clamping and indexing mechanism preferably withstands the autoclave heat and pressure that is typically experienced during the curing part of the manufacturing process.

Abstract: The present invention provides an automated fiber joint placement machine mandrel configuration where the lap joint is preferably parallel to the mold surface. Accordingly, the user may shim the mandrel segments without otherwise affecting the integrity of the seal. A lap joint is preferably utilized wherein mandrel segments are split at the stringer centerline through the middle of the hat or through the cap of the stringer. The lap joint is preferably designed such that the face sheets of the mandrel segments preferably lie flat on top of one another when placed in contact. The seal plane is thus protected.

Abstract: A system and method for making and using composite material components is disclosed. Composite material components are preferably constructed in patterns where every part needed for a given filler is included in a single series pattern. Using these series patterns, the material can be cut, folded and the parts created in a manner such that the individual parts forming a single filler are releasably attached to one another, thus resulting in effective and efficient organization of these parts. The filler panels can then be arranged into a folding stack of offset edges. Two shapes are preferably used with subtle differences between each at the fold area. Different patterns can be used to have the first two panels in the series positioned at 0 degrees, followed by two panels positioned at 45 degrees, and then alternating the angle positions throughout the pattern. The pattern preferably incorporates triangular portions or tabs between each set of panels in the series to help in establishing a fold line.

Abstract: A system for verifying a part disclosed. The system comprises a virtual part and a virtual gage associated with the virtual part. A physical part corresponds to the virtual part. A digitized part is generated from the physical part, and the virtual gage evaluates the digitized part. A method for verifying a part is disclosed. A virtual part is provided. A virtual gage associated with the virtual part is generated. A physical part corresponding to the virtual part is produced. A digitized part is generated from the physical part. The digitized part is evaluated with the virtual gage.

Abstract: An apparatus (100) for fabricating composite structures is provided that includes first and second tooling portions (110, 120) that are configured to support at least one layer (160) of composite materials during curing to form a composite structure. The apparatus (100) further includes a flexible hinge (140) that is disposed between and couples the first and second tooling portions (110, 120). The flexible hinge (140) couples the tooling portions (110, 120) such that they may be peeled away from the composite material after curing by bending the apparatus (100) at the flexible hinge (140).

Abstract: A system for part measurement and verification is disclosed. The system comprises a set of design criteria specifying a part and a fixture with gage blocks for positioning the part, where each of the gage blocks represents a known position. At least one probe is operable to measure the scalar values of the part and the gage blocks. A handheld information processor or computer is coupled to the probe for receiving the measurements and is operable to transform the measurements and compare those measurements to the design criteria to in order to verify the part. A method for part measurement and verification is disclosed. The method comprises eight steps. Step one calls for specifying the part with a set of design criteria. Step two requires storing the design criteria in a handheld information processor. Step three provides placing the part in a fixture with gage blocks at known locations. In step four, the method provides for configuring the handheld information processor to receive part measurements.

Abstract: A system and method for aligning aircraft coordinate systems includes determining a first coordinate in the first coordinate system from a first reflector using a first coordinate positioning device, and determining second and third coordinates in the second coordinate system from second and third reflectors, respectively, using a second coordinate positioning device. The second and third reflectors are disposed at predetermined distances from the first reflector. The system aligns the first and second coordinate systems based on the first, second, and third coordinates and the predetermined distances using a processor.

Abstract: A system for part measurement and verification is disclosed. The system comprises a set of design criteria specifying a part and a fixture with gage blocks for positioning the part, where each of the gage blocks represents a known position. At least one probe is operable to measure the scalar values of the part and the gage blocks. A handheld information processor or computer is coupled to the probe for receiving the measurements and is operable to transform the measurements and compare those measurements to the design criteria to in order to verify the part. A method for part measurement and verification is disclosed. The method comprises eight steps. Step one calls for specifying the part with a set of design criteria. Step two requires storing the design criteria in a handheld information processor. Step three provides placing the part in a fixture with gage blocks at known locations. In step four, the method provides for configuring the handheld information processor to receive part measurements.

Abstract: A material management system and method (10) includes a data storage device (20) containing order information (24) for a product, product information (26) for a product, work center information (28) for fabricating the product, and inventory information (30) for fabricating the product. The system (10) also includes a processor (12) coupled to the data storage device (20). The system (10) further includes a nesting application (22) operable for execution by the processor (12). The nesting application (22) is operable to determine a fabrication nest for the product using the order information (24), the product information (26), the work center information (28), or the inventory information (30).

Abstract: According to one embodiment of the invention, a system for bending a structural member includes a base, a pair of pivot plates rotationally coupled to the base, an actuator coupled between the pair of pivot plates, and a plurality of adjustable supports adjustably coupled to the pair of pivot plates. The adjustable supports are adjustable in a transverse direction, and are operable to bend the structural member through a rotation of the pivot plates.

Abstract: A heat absorbing coating having a plurality of micro-capsules each being an encapsulant shell and a heat absorbing material within the shell, and a carrier adherable to a substrate and throughout which the micro-capsules are dispersed. The heat absorbing material is preferably a phase change material and can be non-limitedly chosen from the group consisting of polyethylene, polypropylene, polywax, and combinations thereof. Shell material can be a metal such as copper, for example, or a polymer. The carrier can be a sprayable polymer mix which provides significant efficacy in uniform application to a substrate. An inventive substrate structure, such as an aircraft structure for example, has thereon the above-defined coating in an amount sufficient to absorb a sufficient amount of heat from the substrate to substantially inhibit thermal erosion in normal operating environments.

Abstract: A system for part measurement and verification is disclosed. The system comprises a set of design criteria specifying a part and a fixture with gage blocks for positioning the part, where each of the gage blocks represents a known position. At least one probe is operable to measure the scalar values of the part and the gage blocks. A handheld information processor or computer is coupled to the probe for receiving the measurements and is operable to transform the measurements and compare those measurements to the design criteria to in order to verify the part.

Abstract: A system and method for aligning aircraft coordinate systems includes determining a first coordinate in the first coordinate system from a first reflector using a first coordinate positioning device, and determining second and third coordinates in the second coordinate system from second and third reflectors, respectively, using a second coordinate positioning device. The second and third reflectors are disposed at predetermined distances from the first reflector. The system aligns the first and second coordinate systems based on the first, second, and third coordinates and the predetermined distances using a processor.

Abstract: An orientation maintained fastener delivery system (10) includes an escapement (14), a transfer system (16), and an injector (18). The escapement (14) regulates the flow of fasteners (20) through the orientation maintained fastener delivery system (10). The escapement (14) also delivers fasteners (20) in a desired orientation to the transfer system (16). The transfer system (16) includes a plurality of tubes (26,30) and a distributor (28). The tubes (26,30) maintain the desired orientation of the fasteners (20) as the fasteners (20) are transported to the injector (18). The distributor (28) aligns a tube (26) coupled to the escapement (14) with a tube (30) coupled to the injector (18). The injector (18) receives fasteners (20) from the transfer system (16) in the desired orientation and delivers the fasteners (20) in the desired orientation to an installation device (22).

Abstract: A top load threaded bolt assembly (60) for restraining a workpiece (36) on a operating surface (32) of a tooling fixture (50) is provided. Top load threaded bolt assembly (60) includes a housing (66) having a bolt cavity (75) and a bolt passage (76) disposed within housing (66). A bolt (64) having a first threaded portion (70) is disposed within bolt cavity (75) such that first threaded portion (70) extends above a operating surface (32) of tooling fixture (50). The top load threaded bolt assembly (60) may be disposed in the operating surface (32) of tooling fixture (50). Top load threaded bolt assembly (60) may further include a conical spring (62) to bias bolt (64) in an extended position. Bolt (64) may be secured in a non-extended position by threading a second threaded portion (72) into a threaded passage (58) which is adjacent bolt cavity (75) and opposite bolt passage (76).

Abstract: A microporous sheet having both acoustical and structural functionality and a process for producing the sheet. Construction of the sheet requires, first of all, providing a sheet capable of functioning as a structural element of a component. A laser device capable of producing a free electron laser beam is provided, and the free electron laser beam is directed to a surface of the sheet to penetrate the sheet at a plurality of sites and thereby form a plurality of apertures. These apertures are generally uniformly dispersed and of a size and number sufficient to enable the sheet to function as an acoustical noise suppressor while retaining capability of functioning as a structural element.

Abstract: A method for fabricating composite structures is provided that includes providing a skin (20) that has at least one layer (160) of uncured composite material, and providing a flexible hinge tool (100) that has first and second tooling portions (110, 120) coupled with a flexible hinge (140). The first and second tooling portions (110, 120) of the hinge tool (100) each have a molding surface (112, 122), and the tooling portions (110, 120) are configured to form at least a portion of a stiffening member (10). The method further includes laying up at least one layer (160) of uncured composite material on the molding surfaces (112, 122) to form the stiffening member (10).