Abstract: Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.

Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.

Abstract: An example method for simultaneously manufacturing a plurality of objects is described. The method includes simultaneously cycling a plurality of pallets through a conveyor system. The conveyor system is cyclical, and the conveyor system includes an entrance point for each pallet, an exit point, and a plurality of manufacturing points corresponding to a plurality of manufacturing devices. Simultaneously cycling the plurality of pallets includes simultaneously cycling the plurality of pallets past the plurality of manufacturing points for two or more cycles, wherein each pallet is associated with a set of manufacturing instructions for a corresponding object. The method further includes, while simultaneously cycling the plurality of pallets through the conveyor system, using a different combination of the plurality of manufacturing devices to manufacture each object in accordance with the set of manufacturing instructions associated with each pallet, thereby manufacturing different objects for each pallet.

Abstract: Systems and methods are provided for assembling a section of a fuselage of an aircraft. The method includes pulsing a half barrel section of the fuselage along a track in a process direction, utilizing an indexing feature associated with the half barrel section to determine a desired contour for a portion of the half barrel section, and enforcing the desired contour onto the half barrel section using components that enforce an inner mold line and components that enforce an outer mold line when the half barrel section is out of tolerance from the desired contour.

Abstract: Methods and apparatus involved in the process of hardening a composite part are disclosed herein. The methods include applying a preform to a mandrel, covering the preform with a caul plate, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel and hardening the preform into a composite part while the caul plate is held against the preform. The apparatus include a mandrel, a caul plate which defines a surface of a preform and where the caul plate may include a rigid material and seals disposed between the mandrel and the caul plate. In an additional aspect, the apparatus may include a sealed chamber with a mandrel and a caul plate and a circumferential seal between the mandrel and the caul plate.

Abstract: Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.

Abstract: Systems and methods are provided for fabricating a fuselage of an aircraft. The method includes: disposing arcuate sections of fuselage at a track of a factory such that concavities of the arcuate sections of the fuselage face a floor of the factory, and bearing edges of the arcuate sections of fuselage directly contact the track; advancing the arcuate sections of fuselage synchronously along the track in a process direction; and performing work within concavities of the arcuate sections of fuselage during pauses between pulses of the arcuate section of fuselage via stations that are disposed beneath the concavities and that are directly mounted to the floor of the factory.

Abstract: Systems and methods are provided for fabrication of frames for aircraft.

Abstract: Systems and methods are provided for fabricating a wing panel. Methods include aligning a strongback over a wing panel, vacuum attaching a wing panel surface and pogos extending beneath the strongback, and adjusting the length of pogos to enforce a contour to the wing panel. Systems include a strongback to extend over a wing panel, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Other systems include a track, work stations along the track, a strongback to extend over the wing panel and move along the track, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Apparatus includes a shuttle having adapters that mate the shuttle with a track, adjustable-length carriers with vacuum couplers to couple with a wing panel surface, and indexing units that interact with indexing features in a manufacturing excess of the wing panel.

Abstract: Systems and methods are provided for assembly line processing of aircraft wing panels. The method includes inputting wing panels into an assembly line, the assembly line having a number of work stations, the wing panels oriented such that leading edges are all on a first side of the work stations, and trailing edges are all on a second side of the work stations, and advancing the wing panels in a process direction through the number of work stations, at least a first portion of the work stations dedicated to wing panel leading edge processing, and a second portion of the work stations dedicated to wing panel trailing edge processing.

Abstract: Systems and methods are provided for assembling an airframe of an aircraft, including receiving a half barrel section of fuselage, advancing the half barrel section in a process direction across multiple stations to separately and simultaneously perform work on the half barrel sections, and subsequently joining the half barrel segments to form a section of the airframe. Each pair of half barrel sections, such as upper and lower half barrels, are progressed through assembly line processes to be delivered to a joining station for joining the half barrels together to form a circumferential section of the fuselage. Multiple joined circumferential sections are joined together to form an elongated extent of the fuselage. Indexing features are provided in the assembly process to monitor and control the progression of the half barrel sections in the work stations of the assembly line process.

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 self-threading lamination head has a material supply drum, a backing layer collection drum, and a material threading system. The material supply drum supports a material roll of layup material backed by a backing layer. The material threading system includes at least one threading belt located on one side of the lamination head. The threading belt is supported by belt rollers driven by a belt drive motor. A belt-mounted layer engagement device is coupled to the threading belt for engaging a backing layer leading edge portion. The backing layer collection drum collects the backing layer as the lamination head applies the layup material onto a substrate. The belt drive motor drives the threading belt over the belt rollers and causes the belt-mounted layer engagement device to thread the backing layer through the lamination head, and position the backing layer leading edge portion proximate the backing layer collection drum.

Abstract: Systems, methods, and apparatus are provided for assembling a wing. Methods include coupling a robot arm to a bracket on a rib held against a wing panel, and operating the coupled robot arm to install shims between the rib and wing panel. Some methods further include mounting (e.g. detachably) the bracket, such as by aligning it with indexing features at the rib. In some methods, the bracket enforces a contour to the rib. Systems include a carriage coupled to a rib, and a robot arm extending therefrom that is operable to perform work (e.g. inspection, installing shims and/or fasteners, etc.) at an interface between the rib and a wing panel. Apparatus includes a robot arm dimensioned for placement at an interface between a rib and a wing panel, with the robot arm including an end effector to perform work upon the interface (e.g. inspection, installing shims and/or fasteners, etc.).

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 and methods are provided for aircraft assembly. The method includes receiving a half barrel section of fuselage in an assembly line having a plurality of serially arranged work stations; advancing the half barrel section in a process direction through the assembly line such that the half barrel section extends across at least a portion of the work stations; and performing work on the half barrel section with the portion of the work stations simultaneously.

Abstract: Systems and methods are provided for demolding a composite part from a mandrel. The method includes mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has been hardened onto a mandrel, mechanically coupling a second arm of an extraction tool to a second arcuate portion of the composite part, and separating the composite part from the mandrel by iteratively performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm, and elastically straining the second arcuate portion of the composite part via the second arm.

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: Systems and methods are provided for placing preforms onto a mandrel. One illustrative method includes moving a mandrel in a process direction relative to a station(s) that comprises multiple pick-and-place machine(s), identifying a tray that stores a preform comprising an unhardened fiber-reinforced material, placing the strong back at the preform via at least one of the pick-and-place machine(s), applying a vacuum to hold the preform in contact with the strong back, transporting the preform to a mandrel via the pick-and-place machine(s), and placing the preform onto the mandrel.

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.