Abstract: A drape forming apparatus for use in forming a composite structure. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool receives at least one layer of composite material over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.

Abstract: Core structures (120) for composite panels (75) of an aircraft (10), composite panels (75) and aircraft (10) including the core structures (120), and methods (200) of manufacturing the composite panels (75) are disclosed herein. The core structures (120) include a first side (140), a second side (150), and a connecting region (160) that interconnects an upper portion (142) of the first side (140) with an upper portion (152) of the second side (150). The first side (140), the second side (150), and the connecting region (160) at least partially define an antenna housing (62), which defines a housing volume (64) configured to contain an aircraft antenna (60) of the aircraft (10), and an electromagnetic wave transmission region (66) configured to permit electromagnetic waves to pass therethrough.

Abstract: A tool assembly includes a support frame including support beams and support mounts supporting the support beams. The support frame is rigid and used to transport the tool assembly. A support tool is supported by the support frame and includes a faceplate and a supporting grid structure formed with the faceplate as a monolithic structure defined by a series of AM layers. The faceplate has a supporting surface at a top of the support tool for supporting a working component. The supporting grid structure engages the support beams such that loads are transferred between the support tool and the support frame through the support beams. The support frame maintains dimensional stability of the support tool during transport and when resting within an allowable tolerance of the support tool.

Abstract: Core structures (120) for composite panels (75) of an aircraft (10), composite panels (75) and aircraft (10) including the core structures (120), and methods (200) of manufacturing the composite panels (75) are disclosed herein. The core structures (120) include a first side (140), a second side (150), and a connecting region (160) that interconnects an upper portion (142) of the first side (140) with an upper portion (152) of the second side (150). The first side (140), the second side (150), and the connecting region (160) at least partially define an antenna housing (62), which defines a housing volume (64) configured to contain an aircraft antenna (60) of the aircraft (10), and an electromagnetic wave transmission region (66) configured to permit electromagnetic waves to pass therethrough.

Abstract: A drape forming apparatus for that includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material over the upper forming surface. The apparatus includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot receives a flange portion of the layer of composite material, and the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus includes a pressurized bladder that extends over the forming tool and the upper plate. The pressurized bladder forces the flange portion against the side forming surface as the flange forming device translates relative to the forming tool.

Abstract: A tool assembly includes a support frame including support beams and support mounts supporting the support beams. The support frame is rigid and used to transport the tool assembly. A support tool is supported by the support frame and includes a faceplate and a supporting grid structure formed with the faceplate as a monolithic structure defined by a series of AM layers. The faceplate has a supporting surface at a top of the support tool for supporting a working component. The supporting grid structure engages the support beams such that loads are transferred between the support tool and the support frame through the support beams. The support frame maintains dimensional stability of the support tool during transport and when resting within an allowable tolerance of the support tool.

Abstract: A drape forming apparatus for use in forming a composite structure is provided. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool is configured to receive at least one layer of composite material extending over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.

Abstract: A drape forming apparatus for use in forming a composite structure is provided. The apparatus includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material extending over the upper forming surface. The apparatus further includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot for receiving a flange portion of the layer of composite material, and wherein the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus further includes a pressurized bladder configured to extend over the forming tool and the upper plate of the flange forming device.