Abstract: An apparatus for fabricating a composite structure includes a tape placement machine including a delivery head configured to dispose a composite tape and a backing plate coupled to the tape placement machine and selectively located relative to the delivery head to react to a placement force applied by the tape placement machine as the composite tape is being disposed.

Abstract: A method for fabricating a composite structure includes steps of: (1) laying up, with a delivery head of a tape placement machine, a continuous segment of a composite tape on a composite panel to form a flange portion of an initial ply of a composite stiffener; (2) locating a backing plate, coupled to the delivery head, relative to the delivery head and the composite panel; and (3) further layup up, with the delivery head, the continuous segment of the composite tape on the backing plate to form a web portion of the initial ply of the composite stiffener.

Abstract: A method for fabricating a composite structure includes steps of: (1) laying up, with a delivery head of a tape placement machine, a continuous segment of a composite tape on a composite panel to form a flange portion of an initial ply of a composite stiffener; (2) locating a backing plate, coupled to the delivery head, relative to the delivery head and the composite panel; and (3) further layup up, with the delivery head, the continuous segment of the composite tape on the backing plate to form a web portion of the initial ply of the composite stiffener.

Abstract: An apparatus for fabricating a composite structure includes a tape placement machine including a delivery head configured to dispose a composite tape and a backing plate coupled to the tape placement machine and selectively located relative to the delivery head to react to a placement force applied by the tape placement machine as the composite tape is being disposed.

Abstract: A fastening system includes a fastener having a head portion and a shaft portion, wherein the head portion has a recess (e.g., a removal tool recess), and an insert (e.g., a plastic insert) having an insert shape substantially equal to the recess shape and an insert thickness substantially equal to or less than the recess depth, wherein the insert is configured to removeably seat within the recess of the head portion. In this way, the insert may be later removed from the recess, allowing easy tool access even in applications where an overlying fairing material or other such conformal coating is used.

Abstract: A fastening system includes a fastener having a head portion and a shaft portion, wherein the head portion has a recess (e.g., a removal tool recess), and an insert (e.g., a plastic insert) having an insert shape substantially equal to the recess shape and an insert thickness substantially equal to or less than the recess depth, wherein the insert is configured to removeably seat within the recess of the head portion. In this way, the insert may be later removed from the recess, allowing easy tool access even in applications where an overlying fairing material or other such conformal coating is used.