Abstract: A tubular material application system for applying a tubular material onto an elongate mandrel includes a gripper system including a first gripper and a second gripper configured to move with inchworm-type movement along an elongated mandrel and incrementally apply a tubular material onto the mandrel to thereby result in a tubular material-mandrel assembly.

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: A downhole system includes a first tubular having a terminal end including a first connector portion, an inlet, an inner surface, an outer surface, and a first conduit extending between the inner surface and the outer surface fluidically exposed at the terminal end. A second tubular including a terminal end section having a second connector portion coupled to the first connector portion to form a joint, an inner surface section, an outer surface section, and a second conduit extending between the inner surface section and the outer surface section and fluidically exposed at the terminal end section. The first conduit is fluidically connected to the second conduit across the joint.

Abstract: Described are methods and systems for manufacturing curved composite stringers. Such composite stringers may have in-plane and/or out-of-plane bends, which are formed while shaping composite charges. Specifically, a composite charge is shaped using a pallet, comprising a plurality of independent pallet portions, rotatably coupled to each other. A hat portion is formed when a part of this charge is conformed to a cavity in the pallet. The pallet portions are rotated relative to each other while forming the hat portion and/or when the hat portion already conforms to the cavity. In some examples, the die is bent together with the charge, when the pallet portions are rotated. This rotation produces one or more of in-plane and/or out-of-plane bends. In some examples, flange portions of the composite charge are positioned in a temporary orientation, e.g., to enable bending of the charge and reduce wrinkles.

Abstract: A manufacturing system includes a first mandrel, a second mandrel, and laminate securing mechanisms. The first mandrel has a first mandrel surface and a first mandrel surface edge. The second mandrel has a second mandrel surface and a second mandrel surface edge, and is positionable in a closed position in which the first mandrel surface edge and the second mandrel surface edge are in contact to form a continuous mandrel surface collectively defined by the first mandrel surface and the second mandrel surface. The second mandrel translates to an open position defining a gap between the first mandrel surface edge and the second mandrel surface edge for receiving a forming die. The laminate securing mechanisms secure the composite laminate on at least one of the first mandrel and the second mandrel during trimming and/or forming of the composite laminate.

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station.

Abstract: A lamination head having bi-directional layup capability has a material supply drum configured to support a material roll of backed material which is comprised of layup material backed by a backing layer. A backing layer separation assembly receives the backed material from the material supply drum and has a backing layer directional control device and first and second backing layer separation mechanisms. The backing layer directional control device in the first mode separation position is aligned with the first backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a first direction of travel. The backing layer directional control device in the second mode separation position is aligned with the second backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a second direction of travel.

Abstract: An ergonomic frame-filler placement tool is manually operable to supply a vacuum fluid flow at a distal end of the tool that can be used by a worker to pick up and hold a piece of frame-filler material to the distal end of the tool, which enables the worker to manipulate the tool to position the piece of frame-filler material over a desired location of a fuselage mandrel and then manually stop the vacuum fluid flow at the distal end of the tool to position the piece of frame-filler material at the desired location on the mandrel.

Abstract: A downhole system includes a first tubular having a terminal end including a first connector portion, an inlet, an inner surface, an outer surface, and a first conduit extending between the inner surface and the outer surface fluidically exposed at the terminal end. A second tubular including a terminal end section having a second connector portion coupled to the first connector portion to form a joint, an inner surface section, an outer surface section, and a second conduit extending between the inner surface section and the outer surface section and fluidically exposed at the terminal end section. The first conduit is fluidically connected to the second conduit across the joint.

Abstract: A lamination head has a material supply drum, a backing layer collection drum, and a backing layer separation assembly. The material supply drum supports a material roll of backed material comprising layup material backed by a backing layer. The backing layer collection drum moves from a collection drum home position to a collection drum engagement position proximate the material supply drum, engage a backing layer leading edge on the material roll, and moves back to the collection drum home position while dispensing a threadable portion of at least the backing layer. The backing layer separation assembly has a backing layer separation device and a backing layer separation mechanism. The backing layer separation device translates from a separation device home position to a separation device engagement position and pulls the threadable portion into proximity to the backing layer separation mechanism for separating the backing layer from the layup material.

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station.

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: Composite parts including hybrid plies, methods of forming the composite parts, and systems for forming the composite parts are disclosed herein. The composite parts include a plurality of plies of composite material. At least one ply is a hybrid ply. The hybrid ply is defined by a plurality of distinct ply tiles, and at least one distinct ply tile in the plurality of distinct ply tiles defines at least one ply tile property that differs from a corresponding ply tile property of at least one other distinct ply tile in the plurality of distinct ply tiles. The methods include selecting at least one distinct ply tile and positioning the at least one distinct ply tile. The methods also include selecting a least one other distinct ply tile and positioning the at least one other distinct ply tile. The systems include systems that define the composite parts and/or perform the methods.

Abstract: A manufacturing system includes a plurality of lamination heads statically positioned in end-to-end relation to each other and defining a lamination station, and configured to dispense a layup material along a dispensing direction. The manufacturing system also includes a lamination surface movable underneath the lamination station. The lamination heads are configured to sequentially apply the layup material onto the lamination surface and onto previously applied layup material as the lamination surface passes through the lamination station to thereby form a composite laminate having a stack of composite plies arranged in a desired ply stacking sequence defined by positions of the lamination heads relative to each other within the lamination station. The manufacturing system further includes one or more trimming devices configured to trim the composite laminate.

Abstract: A lamination head having bi-directional layup capability has a material supply drum configured to support a material roll of backed material which is comprised of layup material backed by a backing layer. A backing layer separation assembly receives the backed material from the material supply drum and has a backing layer directional control device and first and second backing layer separation mechanisms. The backing layer directional control device in the first mode separation position is aligned with the first backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a first direction of travel. The backing layer directional control device in the second mode separation position is aligned with the second backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a second direction of travel.

Abstract: A lamination head has a material supply drum, a backing layer collection drum, and a backing layer separation assembly. The material supply drum supports a material roll of backed material comprising layup material backed by a backing layer. The backing layer collection drum moves from a collection drum home position to a collection drum engagement position proximate the material supply drum, engage a backing layer leading edge on the material roll, and moves back to the collection drum home position while dispensing a threadable portion of at least the backing layer. The backing layer separation assembly has a backing layer separation device and a backing layer separation mechanism. The backing layer separation device translates from a separation device home position to a separation device engagement position and pulls the threadable portion into proximity to the backing layer separation mechanism for separating the backing layer from the layup material.

Abstract: A manufacturing system includes a first mandrel, a second mandrel, and laminate securing mechanisms. The first mandrel has a first mandrel surface and a first mandrel surface edge. The second mandrel has a second mandrel surface and a second mandrel surface edge, and is positionable in a closed position in which the first mandrel surface edge and the second mandrel surface edge are in contact to form a continuous mandrel surface collectively defined by the first mandrel surface and the second mandrel surface. The second mandrel translates to an open position defining a gap between the first mandrel surface edge and the second mandrel surface edge for receiving a forming die. The laminate securing mechanisms secure the composite laminate on at least one of the first mandrel and the second mandrel during trimming and/or forming of the composite laminate.

Abstract: Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.

Abstract: A system and method are provided to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Abstract: An apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.