Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Abstract: Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.

Abstract: There is provided an automated removal apparatus for selectively removing one or more trimmed portions of a laminated ply in a ply-by-ply fabrication process. The automated removal apparatus includes a rotatable reel having a plurality of retractable vacuum panels attached around the rotatable reel. Each retractable vacuum panel has one or more retractable vacuum pad assemblies, and each retractable vacuum pad assembly has a vacuum pad with a vacuum port and a self-sealing valve. The automated removal apparatus further includes actuator assemblies attached to the plurality of retractable vacuum panels, friction reducing elements attached around the rotatable reel, a drive assembly attached to the rotatable reel, and a pneumatic system attached to the rotatable reel and including a valve manifold operable to control an air flow to the actuator assemblies and to one or more vacuum generators to generate a vacuum flow.

Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.

Abstract: A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.

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 system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly.

Abstract: Systems are provided for fabricating a preform for a fuselage section of an aircraft. The system includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.

Abstract: A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

Abstract: Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

Abstract: A tubular material application system for applying a tubular material onto an elongate mandrel includes a gripper system including a first gripper and a second gripper configured to move with inchworm-type movement along an elongated mandrel and incrementally apply a tubular material onto the mandrel to thereby result in a tubular material-mandrel assembly.

Abstract: A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.

Abstract: A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.

Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.

Abstract: An ergonomic frame-filler placement tool is manually operable to supply a vacuum fluid flow at a distal end of the tool that can be used by a worker to pick up and hold a piece of frame-filler material to the distal end of the tool, which enables the worker to manipulate the tool to position the piece of frame-filler material over a desired location of a fuselage mandrel and then manually stop the vacuum fluid flow at the distal end of the tool to position the piece of frame-filler material at the desired location on the mandrel.

Abstract: A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.

Abstract: Systems and methods are provided for fabricating a part on a mandrel. The system includes a series of stations divided into at least two groups of stations, wherein each group of stations performs fabrication operations on a particular zone of the mandrel.