Abstract: A method for forming a structural member and a structural member produced thereby includes positioning a first composite section and a second composite section within a tool. The tool has an inner surface and a wall intersection and is supported by a tool platform. The tool platform and a pressure platform are relatively movable between an open position and a closed position. The tool has a non-planar outer surface against which the member may be pressed. A composite splice member is positioned at least partially overlapping both the first composite section and the second composite section to form a joint in the composite structural member. The composite structural member is pressed against the non-planar outer surface of the tool by applying pressure to the joint from a pressure bladder. Heat is applied to the composite structural member at the joint to cure the composite splice member to the first composite section and the second composite section.

Abstract: A system includes a frame having spaced apart first and second upright members, and a robot including an end effector and a plurality of arms. The arms extend from the end effector and clamp onto the first and second frame members to position the end effector between the first and second frame members.

Abstract: A facility for assembling aircraft fuselages comprises a plurality of movable cradles. Each cradle is configured to support a fuselage keel structure and assemble a panelized fuselage from the keel structure to obtain a full fuselage contour in a single upright build position.

Abstract: A facility for assembling aircraft fuselages comprises a plurality of movable cradles. Each cradle is configured to support a fuselage keel structure and assemble a panelized fuselage from the keel structure to obtain a full fuselage contour in a single upright build position.

Abstract: A method of assembling a panelized aircraft fuselage comprises loading a keel structure on a cradle; attaching stanchions to a floor grid; positioning the floor grid and stanchions over the keel structure and attaching the stanchions to the keel structure; obtaining a full fuselage contour including locating lower panels on the floor grid while using the cradle, the floor grid, and the keel structure to support the lower panels, and locating upper panels on the lower panels; and fastening the lower panels to the keel structure and the upper panels. The fuselage is assembled upright from the keel structure without changing orientation of the fuselage.

Abstract: A method for forming a structural member and a structural member produced thereby includes positioning a first composite section and a second composite section within a tool. The tool has an inner surface and a wall intersection and is supported by a tool platform. The tool platform and a pressure platform are relatively movable between an open position and a closed position. The tool has a non-planar outer surface against which the member may be pressed. A composite splice member is positioned at least partially overlapping both the first composite section and the second composite section to form a joint in the composite structural member. The composite structural member is pressed against the non-planar outer surface of the tool by applying pressure to the joint from a pressure bladder. Heat is applied to the composite structural member at the joint to cure the composite splice member to the first composite section and the second composite section.

Abstract: A system includes a frame having spaced apart first and second upright members, and a robot including an end effector and a plurality of arms. The arms extend from the end effector and clamp onto the first and second frame members to position the end effector between the first and second frame members.

Abstract: A facility for assembling aircraft fuselages comprises a plurality of movable cradles. Each cradle is configured to support a fuselage keel structure and assemble a panelized fuselage in a single upright build position.

Abstract: A composite structural member includes first and second composite sections spliced together by an overlapping composite splice member.