Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Abstract: A tensioning system that can be used with a heater blanket and a vacuum bag for heating a workpiece can include a tensioner including at least one flexible rod. The tensioner can further include an end cap positioned on one or both ends of the flexible rod. The tensioner can be inserted through one or more sleeves attached to the vacuum bag, and each end of the flexible rod can be positioned within a pocket and thereby attached to the vacuum bag. In one implementation, the flexible rod can be rotated relative to the one or more end caps to decrease or increase a length of the tensioner, and the length of the tensioner is thereby adjustable. The tension applied to the vacuum bag can mitigate sealing of a seal of the vacuum bag with a layup mandrel.

Abstract: A tensioning system that can be used with a heater blanket and a vacuum bag for heating a workpiece can include a tensioner including at least one flexible rod. The tensioner can further include an end cap positioned on one or both ends of the flexible rod. The tensioner can be inserted through one or more sleeves attached to the vacuum bag, and each end of the flexible rod can be positioned within a pocket and thereby attached to the vacuum bag. In one implementation, the flexible rod can be rotated relative to the one or more end caps to decrease or increase a length of the tensioner, and the length of the tensioner is thereby adjustable. The tension applied to the vacuum bag can mitigate sealing of a seal of the vacuum bag with a layup mandrel.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Abstract: Ply wrinkling during hot drape forming of a composite laminate is reduced at outside corner radii of a forming tool. First and second tensioning materials placed between a composite laminate charge and the forming tool maintain the laminate charge in tension at the radius corners as the charge is formed down over corner radii.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Abstract: A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.

Abstract: Ply wrinkling during hot drape forming of a composite laminate is reduced at outside corner radii of a forming tool. First and second tensioning materials placed between a composite laminate charge and the forming tool maintain the laminate charge in tension at the radius corners as the charge is formed down over corner radii.

Abstract: A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.