Abstract: A method of forming a structure includes positioning a first layer component onto a portion of a top surface of a second layer component and positioning a third layer component onto a portion of a bottom surface of the second layer component to form a layered material assembly. The first layer component and the third layer component are configured to be manufactured of a first fabric and a bio-based resin product, and the second layer component is configured to be manufactured of a second material and the bio-based resin product. The method includes exposing the layered material assembly to one or more curing conditions to create a cured material assembly, and forming the cured material assembly into the structure configured to be disposed onboard an aircraft system.

Abstract: Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

Abstract: Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

Abstract: Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

Abstract: Methods of forming a curvature into a composite stiffener and a forming tool are presented. The composite stiffener is positioned in a forming region created by a base assembly and an upper assembly. A first airflow is applied through the material of the base assembly. A second airflow is applied through the material of the upper assembly. A plurality of brackets of the upper assembly is moved relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener.

Abstract: A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

Abstract: A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

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 stiffener composite charge placement system is presented. The stiffener composite charge placement system comprises a longitudinal end effector having a first attachment point and a second attachment point; a first rotational arm having a first connector configured to connect to the first attachment point; a first movement system configured to move the first rotational arm within a manufacturing environment; a second rotational arm having a second connector configured to connect to the second attachment point; and a second movement system configured to move the second rotational arm within the manufacturing environment.

Abstract: Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

Abstract: Methods of forming a curvature into a composite stiffener and a forming tool are presented. The composite stiffener is positioned in a forming region created by a base assembly and an upper assembly. A first airflow is applied through the material of the base assembly. A second airflow is applied through the material of the upper assembly. A plurality of brackets of the upper assembly is moved relative to each other to change a curvature of the forming region along a length of the forming region to form the curvature into the composite stiffener.

Abstract: A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

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 stiffener composite charge placement system is presented. The stiffener composite charge placement system comprises a longitudinal end effector having a first attachment point and a second attachment point; a first rotational arm having a first connector configured to connect to the first attachment point; a first movement system configured to move the first rotational arm within a manufacturing environment; a second rotational arm having a second connector configured to connect to the second attachment point; and a second movement system configured to move the second rotational arm within the manufacturing environment.

Abstract: A tunable notch filter, comprises a transmission line coupled to an antenna; a plurality of ring resonators inductively coupled to the transmission line, wherein each ring resonator of the plurality of ring resonators is grounded and comprises a variable microelectromechanical systems (MEMS) capacitor; wherein a set of variable MEMS capacitors of the plurality of variable MEMS capacitors are independently tunable to vary a notch location and a notch width of the tunable notch filter; and wherein a set of ring resonators of the plurality of ring resonators further comprises an attenuator configured to reduce power reflected from the antenna.