Abstract: A method of forming a composite material part using an integrated shape memory polymer (SMP) and caul tool comprises the steps of: placing a caul on a positive feature of a mold, deforming the SMP from a relaxed state such that the SMP integrates with the caul to form an integrated SMP and caul tool, placing composite material on the integrated SMP and caul tool, heating the composite material to cure the composite material to form a composite material part while the SMP remains deformed, and stimulating the SMP to return to the relaxed state such that the SMP separates from the caul and the composite material part.

Abstract: A method of forming a composite material part using an integrated shape memory polymer (SMP) and caul tool comprises the steps of: placing a caul on a positive feature of a mold, deforming the SMP from a relaxed state such that the SMP integrates with the caul to form an integrated SMP and caul tool, placing composite material on the integrated SMP and caul tool, heating the composite material to cure the composite material to form a composite material part while the SMP remains deformed, and stimulating the SMP to return to the relaxed state such that the SMP separates from the caul and the composite material part.

Abstract: A system for processing a composite material may comprise a chamber, a mandrel, an upper ramp, and an upper diaphragm. The chamber generally provides structural support while a vacuum is applied to the system and may have a six-sided generally rectangular box shape. The mandrel generally provides support for the composite material, and may be located within the chamber. The upper ramp generally provides a path for the upper diaphragm to follow under vacuum, and may be located adjacent to the mandrel and tilted at approximately 45 degrees downward thereto. The upper diaphragm may be placed over an opening along one side of the chamber. During processing, a vacuum may be applied to chamber and the upper diaphragm may be pulled inward through the opening to press the composite material against the mandrel.

Abstract: A system for processing a composite material may comprise a chamber, a mandrel, an upper ramp, and an upper diaphragm. The chamber generally provides structural support while a vacuum is applied to the system and may have a six-sided generally rectangular box shape. The mandrel generally provides support for the composite material, and may be located within the chamber. The upper ramp generally provides a path for the upper diaphragm to follow under vacuum, and may be located adjacent to the mandrel and tilted at approximately 45 degrees downward thereto. The upper diaphragm may be placed over an opening along one side of the chamber. During processing, a vacuum may be applied to chamber and the upper diaphragm may be pulled inward through the opening to press the composite material against the mandrel.

Abstract: A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: Embodiments of an assembly for securing a stringer to a substrate are provided. The stringer assembly includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: Embodiments of an assembly for securing a stringer to a substrate are provided. The stringer assembly includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: A co-cured composite stringer and associated apparatus and method are provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Abstract: A bonding tool assembly (10) for supporting a composite part structure (11) during fabrication and curing processes, includes a bonding tool (12) and a plurality of fairing bars (14). The bonding tool (12) contains a support surface (16) upon which a composite part structure (11) is placed. The plurality of fairing bars (14) are placed completely around the periphery of the composite part structure (11) providing lateral support. The fairing bars (14) each contain a mating surface (18) which is placed directly upon the support surface (16) of the bonding tool (12). Each mating surface (18) contains a plurality of extended indexing protrusions (20) which form a distinct pattern and are secured by threaded fasteners (21). The support surface (16) contains a plurality of indexing recesses (22) that are configured to form the same pattern as the indexing protrusions (20) such that the fairing bars (14) and the bonding tool (12) are matable.