Abstract: Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes a tool surface configured to support fiber-reinforced resin material and define an outer mold line (OML) of the fiber-reinforced resin material. The movable support system is configured to respond to signals from a controller to automatically change the shape of the tool surface and alter the OML of the finished part to suit the particular application. In one embodiment, the movable support system can include a plurality of telescoping actuators operably coupled to the tool plate.

Abstract: A vessel, such as a wing-integrated aircraft fuel tank. The vessel can include a first surface portion, a second surface portion spaced apart from the first surface portion, and a core positioned between the first and second surface portions. The core can be sealably connected to the first and second surface portions and can be positioned to carry a load from at least one of the first and second surface portions to the other. The core can include a plurality of cells separated by cell walls, at least some of which have wall openings positioned to provide liquid communication between adjacent cells.

Abstract: Stiffened structures and associated methods are disclosed. In one embodiment, an elongated metallic stiffening member can be attached to a composite sheet and positioned to resist bending of the composite sheet. In another embodiment, a structural system can include an elongated composite element attached between a composite sheet and a metallic stiffening member. In still another embodiment, the structural system is formed without attaching a honeycomb stiffening arrangement.

Abstract: Methods and apparatuses for joining structures together are disclosed. In one embodiment, a coupling device is inserted through a first aperture of a first structure and through a second aperture of a second structure. The coupling device can be positioned with a first section of the coupling device extending through the first aperture and a second section of the coupling device extending through the second aperture, but not into the first aperture. A force can be applied to the coupling device to radially expand a portion of the second section of the coupling device toward an interior surface of the second aperture, while the first section of the coupling device in the first aperture remains at least approximately unexpanded in a radial direction or expands by a lesser amount in the radial direction.