Abstract: A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the failing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

Abstract: A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.

Abstract: A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the failing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

Abstract: A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the fairing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

Abstract: A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.

Abstract: A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.

Abstract: A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.

Abstract: A jig apparatus and associated systems and methods for forming a composite wing skin is presented, including providing a frame with a working surface. A plurality of indexing blocks are coupled to the working surface of the frame. Each of the plurality of indexing blocks has a first indexing surface oriented perpendicular to the working surface of the frame and a second indexing surface oriented approximately parallel to the working surface of the frame. A plurality of clamping blocks are also each moveably coupled to one of the plurality of indexing blocks. Each of the plurality of clamping blocks has a clamping surface oriented perpendicular to the working surface of the frame and in facing relation to the first indexing surface of an adjacent indexing block thereby defining a plurality of channels.

Abstract: A method and apparatus for manufacturing a composite structure. The apparatus comprises a base section and a locking section. The base section of a mandrel has a channel with an opening that receives a portion of a bagging material wrapped around an exterior surface of the base section. The locking section of the mandrel engages the channel such that the portion of the bagging material in the channel is held inside the channel.

Abstract: A jig apparatus and associated systems and methods for forming a composite wing skin is presented, including providing a frame with a working surface. A plurality of indexing blocks are coupled to the working surface of the frame. Each of the plurality of indexing blocks has a first indexing surface oriented perpendicular to the working surface of the frame and a second indexing surface oriented approximately parallel to the working surface of the frame. A plurality of clamping blocks are also each moveably coupled to one of the plurality of indexing blocks. Each of the plurality of clamping blocks has a clamping surface oriented perpendicular to the working surface of the frame and in facing relation to the first indexing surface of an adjacent indexing block thereby defining a plurality of channels.

Abstract: A method and associated system for forming composite materials is presented, including providing a composite charge having applied release films to top and bottom surfaces and positioned on a contoured forming tool such that a portion of the composite charge over hangs a second upper surface of forming tool. A fairing bar abuts the forming tool that has an uppermost surface positioned above the second upper surface of the forming tool. The combination of the positioning of the fairing bar and the use of release film in contact with the composite charge allows the composite charge to conform to the contoured forming tool without bridging or wrinkling the composite charge when a forming membrane and applied vacuum are used.

Abstract: A method and apparatus for manufacturing a composite structure. The apparatus comprises a base section and a locking section. The base section of a mandrel has a channel with an opening that receives a portion of a bagging material wrapped around an exterior surface of the base section. The locking section of the mandrel engages the channel such that the portion of the bagging material in the channel is held inside the channel.

Abstract: A mandrel for processing a part comprises an outer sleeve and a generally flexible inner core. The outer sleeve includes at least one flexible portion along its length allowing the sleeve to flex to a desired contour.

Abstract: A mandrel for processing a part comprises an outer sleeve and a generally flexible inner core. The outer sleeve includes at least one flexible portion along its length allowing the sleeve to flex to a desired contour.