Abstract: A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.

Abstract: A tool for making contoured composite hat stringers allows control of stringer wrinkling. The tool includes a set of first openings that allow the tool to flex during contouring of the stringer, and a set of second openings into which portions of the composite charge may strain during the contouring.

Abstract: A tool is configured to form a composite charge into a stringer having a net shape with at least one out-of-place feature. The out-of-plane feature is formed by a shim removably attached to the tool. A family of the shims may be used to form a range of out-of-plane features having varying characteristics.

Abstract: A tool for making contoured composite hat stringers allows control of stringer wrinkling. The tool includes a set of first openings that allow the tool to flex during contouring of the stringer, and a set of second openings into which portions of the composite charge may strain during the contouring.

Abstract: A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.

Abstract: A composite charge positioning assembly configured to position a composite charge onto a forming tool is presented. The composite charge positioning assembly comprises a base; a first charge support arm associated with the base and movable in a first direction towards or away from the base; and a second charge support arm associated with the base and movable in the first direction. The first charge support arm has a first surface configured to contact a portion of a composite charge. The second charge support arm has a second surface configured to contact a second portion of the composite charge.

Abstract: An illustrative embodiment of the present disclosure provides a method. A composite charge is placed over a forming and cure mandrel, a first radius filler, and a second radius filler. Mechanical pressure is applied to shape the composite charge to the forming and cure mandrel and a rigid base to form a stringer layup having a hat-shaped cross-section. Vacuum pressure is applied to the stringer layup to form a compacted stringer package.

Abstract: A composite prepreg laminate such as a hat type-stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

Abstract: An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Abstract: Systems and methods are provided for bi-directional cutters for Automated Fiber Placement (AFP) machines. One embodiment includes a bi-directional cutter for Automated Fiber Placement (AFP) manufacturing. The cutter includes a cutter body that has an upper edge and a lower edge, and has an opening placed between the upper edge and the lower edge that is dimensioned to enable passage of a tow of fiber through the cutter body. The cutter also includes a first blade disposed on the lower edge of the cutter body that is oriented to cut the tow when the cutter is driven downward, and a second blade disposed on an edge of the opening in the cutter body that is oriented to cut the tow when the cutter is driven upward.

Abstract: A composite charge positioning assembly configured to position a composite charge onto a forming tool is presented. The composite charge positioning assembly comprises a base; a first charge support arm associated with the base and movable in a first direction towards or away from the base; and a second charge support arm associated with the base and movable in the first direction. The first charge support arm has a first surface configured to contact a portion of a composite charge. The second charge support arm has a second surface configured to contact a second portion of the composite charge.

Abstract: Apparatus, systems, and methods for placing a part may automatically self-align the part relative to a target along multiple axes of movement, such as along the width of the part, and normal to one or more target surfaces of the target. Devices may include one or more installation heads each having a respective retaining portion configured to selectively support and retain the part in association with the respective installation head as the device moves the part from a first location located apart from the target, towards the target. The installation head may be configured to automatically align the part with the target, in response to engagement between one or more part surfaces of the part and one or more target surfaces of the target. The retaining portion may be configured to selectively release the part once the part is automatically aligned with and operatively at the target.

Abstract: A composite laminate such as a hat-type stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

Abstract: A film tube installed and sealed in a hollow composite part acts as an internal vacuum bag that eliminates the need for an internal mandrel to react compaction forces applied by autoclave pressure during curing of the part.

Abstract: Apparatus, systems, and methods for placing a part may automatically self-align the part relative to a target along multiple axes of movement, such as along the width of the part, and normal to one or more target surfaces of the target. Devices may include one or more installation heads each having a respective retaining portion configured to selectively support and retain the part in association with the respective installation head as the device moves the part from a first location located apart from the target, towards the target. The installation head may be configured to automatically align the part with the target, in response to engagement between one or more part surfaces of the part and one or more target surfaces of the target. The retaining portion may be configured to selectively release the part once the part is automatically aligned with and operatively at the target.

Abstract: An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Abstract: An illustrative embodiment of the present disclosure provides a method. A composite charge is placed over a forming and cure mandrel, a first radius filler, and a second radius filler. Mechanical pressure is applied to shape the composite charge to the forming and cure mandrel and a rigid base to form a stringer layup having a hat-shaped cross-section. Vacuum pressure is applied to the stringer layup to form a compacted stringer package.

Abstract: Within examples, methods and systems for a multi-state bladder or elastomeric apparatus for manufacture of composite material are provided. The elastomeric apparatus includes a housing having a flexible surface state and a rigid surface state, a rod within the housing extending along a length of the housing, and a plurality of components mounted to the rod, such that in an engaged position of the rod the plurality of components cause the housing to have the rigid surface state, and in a disengaged position of the rod the plurality of components enable the housing to have the flexible surface state.

Abstract: Systems and methods are provided for bi-directional cutters for Automated Fiber Placement (AFP) machines. One embodiment includes a bi-directional cutter for Automated Fiber Placement (AFP) manufacturing. The cutter includes a cutter body that has an upper edge and a lower edge, and has an opening placed between the upper edge and the lower edge that is dimensioned to enable passage of a tow of fiber through the cutter body. The cutter also includes a first blade disposed on the lower edge of the cutter body that is oriented to cut the tow when the cutter is driven downward, and a second blade disposed on an edge of the opening in the cutter body that is oriented to cut the tow when the cutter is driven upward.

Abstract: Systems and methods are provided for bi-directional cutters for Automated Fiber Placement (AFP) machines. One embodiment includes a bi-directional cutter for Automated Fiber Placement (AFP) manufacturing. The cutter includes a cutter body that has an upper edge and a lower edge, and has an opening placed between the upper edge and the lower edge that is dimensioned to enable passage of a tow of fiber through the cutter body. The cutter also includes a first blade disposed on the lower edge of the cutter body that is oriented to cut the tow when the cutter is driven downward, and a second blade disposed on an edge of the opening in the cutter body that is oriented to cut the tow when the cutter is driven upward.