Abstract: The invention is a process and apparatus for forming structural members from layers of uncured composite material. The apparatus comprises a first station having at least one tape dispensing module, a second station where tape layers that have been deposited on a tool are vacuum treated in order to remove air entrapped between layers of the tape, and a track system which enables movement of the tool between the first and second stations as well as a tool storage station. The process of building the structural members comprises dispensing tape from each of the modules at the first station onto a tool, then removing entrapped air from between layers of deposited tape, then dispensing further layers of tape, then removing entrapped air, etc., until the desired tape configuration has been achieved. Until such built-up structural member is cured, it is stored in racks in the tool storage station. A unique "partial ply" module is disclosed for applying tape segments to the side forming surfaces of the tool.

Abstract: A process for forming composite hollow crown stiffened skins and panels in which a first layer or skin is placed on a forming surface of a female mold and, after forming a plurality of U-shaped stiffener elements in the first skin, a second skin is placed over the first skin, whereupon the resulting assembly is prepared for autoclave curing. The stiffener elements are formed by pressing the first skin into U-shaped depressions in the female mold surface and inserting a hollow, expandable rubber mandrel into each of the depressions on top of the first skin. Valve stems in the mandrels enable maintaining the pressure inside at atmospheric pressure. The mandrels are maintained in their "pressurized" state during subsequent formation and autoclave curing steps.

Abstract: A process for forming composite hollow crown stiffened skins and panels in which a first layer or skin is placed on a forming surface of a female mold and, after forming a plurality of U-shaped stiffener elements in the first skin, a second skin is placed over the first skin, whereupon the resulting assembly is prepared for autoclave curing. The stiffener elements are formed by pressing the first skin into U-shaped depressions in the female mold surface and inserting a hollow, expandable rubber mandrel into each of the depressions on top of the first skin. Valve stems in the mandrels enable maintaining the pressure inside at atmospheric pressure. The mandrels are maintained in their "pressurized" state during subsequent formation and autoclave curing steps.

Abstract: A process for manufacturing stiffened composite skin panel structures possessing novel hollow crown-shaped stiffener elements, and further including any combination of forward spars, aft spars, and transversely extending shear ties. The novel process embraces fabrication and curing of these structures without the use of mandrels. In practicing the method, the crown-shaped stiffeners, spars and shear ties are integrally bonded to a planar or curved skin structure to provide axial stiffness in semimonocoque components such as aircraft wings, stabilizers, fuselages, etc. The method of fabrication yields highly producible, structurally efficient composite aircraft components.