Abstract: Automated methods of forming composite structures may include applying fibers having various predetermined lengths to a removable backing material to form a net shape or near net shape pattern for forming a composite structure having a varying transverse cross-section. Sheets of composite material may comprise strips of composite material adhered to a backing material in a net shape or near net shape pattern for forming a composite structure with a varying transverse cross-section. Further methods of manufacturing sheets of composite material may comprise applying fibers having various predetermined lengths to a removable backing material in a net shape or near net shape pattern for forming a composite structure having a varying transverse cross-section. Pattern preparation systems may include a material placement device programmed and configured to apply fibers having various predetermined lengths to a removable backing material. Forming systems may include an indicia locating device.

Abstract: Methods of forming a composite structure include conforming at least one ply of material to a forming surface of a tool having differing features. Apparatuses for forming a composite structure include a forming tool and a material feed assembly configured to hold a supply of material, where the material feed assembly may be configured to pivot the supply of material relative to the forming tool. Composite structures having an at least partially annular shape are formed by an at least partially automated process.

Abstract: Methods of forming a composite structure include conforming at least one ply of material to a forming surface of a tool having differing features. Apparatuses for forming a composite structure include a forming tool and a material feed assembly configured to hold a supply of material, where the material feed assembly may be configured to pivot the supply of material relative to the forming tool. Composite structures having an at least partially annular shape are formed by an at least partially automated process.

Abstract: Material preparation devices and related methods include a material or substrate assembly and an application assembly for applying a fiber material.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: Methods of forming a composite structure include conforming at least one ply of material to a forming surface of a tool having differing features. Apparatuses for forming a composite structure include a forming tool and a material feed assembly configured to hold a supply of material, where the material feed assembly may be configured to pivot the supply of material relative to the forming tool. Composite structures having an at least partially annular shape are formed by an at least partially automated process.

Abstract: Material preparation devices and related methods include a material or substrate assembly and an application assembly for applying a fiber material.

Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber-reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second, different orientation relative to an edge of the formed bias-ply.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber-reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second, different orientation relative to an edge of the formed bias-ply.

Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.

Abstract: An automated material delivery system including a material handling assembly, a compaction member, a handling actuator, and a cutting actuator is provided. The material handling assembly is configured and arranged to guide material. The material handling assembly includes a tacking member that is configured and arranged to selectively press the material over a forming surface of a tool. The compaction member is spaced a select distance from the tacking member. The compaction member is further configured to selectively press the material over at least a portion of the forming surface of the tool. The handling actuator is coupled to selectively move at least one of the material handling assembly and the compaction member to move the material handling assembly in relation to the compaction member. The cutting assembly is positioned between the tacking member and the compaction member. The cutting assembly is configured and arranged to selectively cut the material.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: An automated material delivery system including a material handling assembly, a compaction member, a handling actuator, and a cutting actuator is provided. The material handling assembly is configured and arranged to guide material. The material handling assembly includes a tacking member that is configured and arranged to selectively press the material over a forming surface of a tool. The compaction member is spaced a select distance from the tacking member. The compaction member is further configured to selectively press the material over at least a portion of the forming surface of the tool. The handling actuator is coupled to selectively move at least one of the material handling assembly and the compaction member to move the material handling assembly in relation to the compaction member. The cutting assembly is positioned between the tacking member and the compaction member. The cutting assembly is configured and arranged to selectively cut the material.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at 17.5 to 27.5 degrees in relation to an edge of the ply layer.