Abstract: A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.

Abstract: A vehicle relay racing system that employs a dual seat racing chair to allow two drivers to switch driving positions within a single vehicle without physically exiting the vehicle is disclosed. The dual seat racing chair includes a swivel mechanism configured to rotate 180 degrees, and thus allow the two drivers to switch driving positions. In alternative embodiments, a dual seat gaming chair is configured to be used in video gaming or other computer-based gaming applications.

Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.

Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.

Abstract: A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

Abstract: A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.

Abstract: The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Abstract: A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

Abstract: A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.

Abstract: A forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage and a second end effector movably connected to the carriage. The first end effector and second end effector are laterally opposed to each other along the longitudinal axis and the stomp foot is located between the first end effector and the second end effector.

Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.

Abstract: To fabricate a composite item, a device places a composite ply on a curved form at about 0° relative to a longitudinal axis of the form. The form includes a web surface and a cap surface. The device includes a web compaction roller and a set of guides. The web compaction roller compacts a composite material upon the web surface and generate a web ply. The set of guide rollers urges against the cap surface. The compaction roller is directed along the form by the guide rollers.

Abstract: A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

Abstract: A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.

Abstract: A production system for manufacturing a workpiece comprises an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features distributed therealong. The production system further comprises a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece.

Abstract: A one-piece barrel assembly cart includes a right assembly cart base connected with a left assembly cart base and at least three stabilizer rings that are attached to the assembly cart base. The one-piece barrel assembly cart may be used to stabilize a tapered cured composite barrel, for example the large fuselage barrel of the aft section of a large new generation aircraft, such as a 7E7 Boeing airplane. A modular assembly cart includes at least two identical modules. Each of these modules includes a cart base and a stabilizer ring. The diameter of the inner surface of the stabilizer ring may vary as needed. Other modules including a fuselage support may be added. By providing modular assembly carts any shape and size of a one-piece composite barrel may be stabilized after curing of the composite material.

Abstract: A flexible rail machine tool couples temporarily to a structure by vacuum cups and positions a tool head at any desired point over an area. The toolhead can perform operations such as drilling, bolt insertion, and acquisition of dimension data. The flexible rail can conform to surface curvature in one or more axes. Tool head perpendicularity to the structure can be sensed and adjusted as needed. The as-attached position of the rail may be compensated for through coordinate transformation, allowing holes, for example, to be placed with substantial precision.

Abstract: A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

Abstract: A rail system for positioning a toolhead above a workpiece uses a rack cut into one edge of the rail and driven by a pinion gear whose shaft is approximately perpendicular to a workpiece to couple the rail to the toolhead. Multiple rollers placed on the toolhead allow contact between the toolhead and the rail to be effectively continuous despite the cutting away of as much as or more than two-thirds of the rail edge to provide rack teeth. Separating thickness axis containment from transverse with a square rail edge and separate thickness axis and transverse rollers allows the toolhead to follow a rail as the rail flexes over a curved surface with minimal position error. Several variations in rail, bearing, and rack implementation can realize comparable results.