Abstract: Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.

Abstract: Methods and devices of fabricating a stringer for a vehicle. The stringer can be constructed from two charges that are formed together into the stringer. During fabrication, the charges are placed over support members with the ends of each charge extending over a die cavity. The charges are secured and a punch die forces the first ends into the die cavity forming blades of the stringer. The charges are secured thus tensioning the charges during the punch process.

Abstract: Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.

Abstract: Methods and devices of fabricating a stringer for a vehicle. The stringer can be constructed from two charges that are formed together into the stringer. During fabrication, the charges are placed over support members with the ends of each charge extending over a die cavity. The charges are secured and a punch die forces the first ends into the die cavity forming blades of the stringer. The charges are secured thus tensioning the charges during the punch process.