Abstract: A method of preparing a composite article including providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.

Abstract: In one aspect, there is a composite skin for a tiltrotor aircraft including a first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; a second skin; and a honeycomb core disposed between the first skin and the second skin, the honeycomb core comprised of a plurality of honeycomb panels positioned along the longitudinal axis of the first skin, the plurality of honeycomb panels having an array of large cells, each cell having a width of at least 1 cm; wherein the second skin and the honeycomb core have an outer perimeter within the periphery of the first skin.

Abstract: A method of preparing a composite article including providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.

Abstract: A material dispensing system including a first frame and a first application head. The first application head supported by the first frame including a first bias ply assembly comprising a bias ply roll supported on a bias ply dispenser unit, the first bias ply assembly configured to pass bias ply material along a bias path; and a first non-bias ply assembly comprising a non-bias ply roll supported by a non-bias ply dispenser unit, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; wherein the bias path and the non-bias path are substantially parallel. Another aspect provides a material dispensing system including a first frame and a first application head supported thereby; and a second frame and a second application head supported thereby; wherein the first frame and the second frame move in an X direction during operation. Another aspect includes preparing a composite article.

Abstract: One embodiment is an apparatus comprising an aircraft wing; a control surface hingedly connected to a trailing edge of the aircraft wing, wherein a slot is provided between the aircraft wing and the control surface; a seal disposed over the slot, the seal hingedly connected to the aircraft wing; a spring mechanism for preloading the seal against a surface of the control surface such that the gap is sealed with the control surface is in a first position relative to the aircraft wing; and at least one cam blade for lifting the seal from the surface of the control surface as the control surface moves from the first position to a second position relative to the aircraft wing and returning the seal to the surface of the control surface as the control surface moves from the second position to the first position.

Abstract: A door system for a nacelle of a tiltrotor aircraft, the nacelle including a movable proprotor housing rotatable relative to a fixed portion of the nacelle from a forward flight mode to a vertical flight mode and a proprotor gearbox door connected to the movable proprotor housing and pivotably coupled to the fixed portion. The door system including a linkage to pivotably couple the door and the fixed portion of the nacelle; a track assembly mounted to the movable proprotor housing; and a door roller mechanism connected to the proprotor gearbox door. The door roller mechanism traverses the track assembly during rotation of the movable proprotor housing.

Abstract: In one aspect, there is a composite skin for a tiltrotor aircraft including a first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; a second skin; and a honeycomb core disposed between the first skin and the second skin, the honeycomb core comprised of a plurality of honeycomb panels positioned along the longitudinal axis of the first skin, the plurality of honeycomb panels having an array of large cells, each cell having a width of at least 1 cm; wherein the second skin and the honeycomb core have an outer perimeter within the periphery of the first skin.

Abstract: A wing is provided in one example embodiment and may include an outboard rib; a proprotor gearbox, wherein the proprotor gearbox is located inboard of the outboard rib; a fitting attached to the proprotor gearbox; and a conversion actuator, wherein the conversion actuator is attached to the wing and is mechanically coupled to the fitting. The wing may further include a downstop striker in which the downstop striker may be mounted to the fitting and the downstop striker may be between the proprotor gearbox and the conversion actuator. The wing may further include a downstop mounted on a top side of the outboard rib, wherein the downstop and the downstop striker are aligned to be in contact when the proprotor gearbox is positioned in an airplane mode.

Abstract: Described herein is an apparatus comprising an aircraft wing and a trailing edge aerodynamic surface connected to a trailing edge of the aircraft wing via a piston assembly in which the piston assembly holds the trailing edge aerodynamic surface in a neutral position relative to the aircraft wing at a constant supply pressure. The piston assembly may be implemented using a pneumatic piston or a hydraulic piston. A first end of the piston assembly may be connected to the aircraft wing and a second end of the piston assembly may be connected to the trailing edge aerodynamic surface. The piston assembly may include a pressure relief valve which may open or close, raising or lowering the aerodynamic surface, responsive to lift load on the aircraft wing.

Abstract: In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

Abstract: In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a cavity with a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the cavity. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity.

Abstract: A method of manufacturing a tiltrotor wing structure including providing a spar mold having a plurality of bores extending from an exterior surface of the mold to an interior surface of the mold, the plurality of bores corresponding to a plurality of primary coordination holes in a spar member, the spar mold having a periphery defined by a top edge, a bottom edge and outboard ends; selecting a plurality of resin impregnated plies to ensure that the plies continuously extend beyond the periphery of the spar mold; laying the plies in the spar mold; curing the plies in the mold to form a cured spar member that extends beyond the periphery of the spar mold; and accurately drilling a plurality of primary coordination holes in the cured spar member in the spar mold using a tool positioned in the plurality of bores.

Abstract: One embodiment is an apparatus comprising an aircraft wing; a control surface hingedly connected to a trailing edge of the aircraft wing, wherein a slot is provided between the aircraft wing and the control surface; a seal disposed over the slot, the seal hingedly connected to the aircraft wing; a spring mechanism for preloading the seal against a top surface of the control surface such that the gap is sealed with the control surface is in a first position relative to the aircraft wing; and at least one cam blade for lifting the seal from the top surface of the control surface as the control surface moves from the first position to a second position relative to the aircraft wing and returning the seal to the top surface of the control surface as the control surface moves from the second position to the first position.

Abstract: In one aspect, there is provided a spar member for an aircraft wing including a support beam having an interior surface, an exterior surface, and opposing ends configured for an aircraft wing, the interior surface and exterior surface disposed between the opposing ends; and a first spar flange extending generally laterally from the exterior surface, the first spar flange configured for attachment with a first wing skin. The first spar flange can be an upper or lower spar flange. In some embodiments, the first spar flange is at an acute angle relative to the exterior surface of the support beam. In certain embodiments, the first spar flange is at an angle of from about 50 degrees to about 85 degrees relative to the exterior surface of the support beam.

Abstract: Embodiments include an apparatus comprising an aircraft wing and a trailing edge aerodynamic surface connected to a trailing edge of the aircraft wing via a piston assembly in which the piston assembly holds the trailing edge aerodynamic surface in a neutral position relative to the aircraft wing at a constant supply pressure. The piston assembly may be implemented using a pneumatic piston or a hydraulic piston. A first end of the piston assembly may be connected to the aircraft wing and a second end of the piston assembly may be connected to the trailing edge aerodynamic surface. The piston assembly may include a pressure relief valve which may open or close, raising or lowering the aerodynamic surface, responsive to lift load on the aircraft wing.

Abstract: A wing is provided in one example embodiment and may include an outboard rib; a proprotor gearbox, wherein the proprotor gearbox is located inboard of the outboard rib; a fitting attached to the proprotor gearbox; and a conversion actuator, wherein the conversion actuator is attached to the wing and is mechanically coupled to the fitting. The wing may further include a downstop striker in which the downstop striker may be mounted to the fitting and the downstop striker may be between the proprotor gearbox and the conversion actuator. The wing may further include a downstop mounted on a top side of the outboard rib, wherein the downstop and the downstop striker are aligned to be in contact when the proprotor gearbox is positioned in an airplane mode.

Abstract: A material dispensing system including a first frame and a first application head. The first application head supported by the first frame including a first bias ply assembly comprising a bias ply roll supported on a bias ply dispenser unit, the first bias ply assembly configured to pass bias ply material along a bias path; and a first non-bias ply assembly comprising a non-bias ply roll supported by a non-bias ply dispenser unit, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; wherein the bias path and the non-bias path are substantially parallel. Another aspect provides a material dispensing system including a first frame and a first application head supported thereby; and a second frame and a second application head supported thereby; wherein the first frame and the second frame move in an X direction during operation. Another aspect includes preparing a composite article.

Abstract: A wing is provided in one example embodiment and may include an upper skin portion; a lower skin portion; and a multi-spar element that extends between the upper skin portion and the lower skin portion, wherein the multi-spar element comprises a plurality of spar elements integrated together. The multi-spar element may include at least one spar element that extends between the upper skin portion and the lower skin portion, wherein the at least one spar element is continuously connected along a forward and aft directional axis to at least one other spar element that extends between the upper skin portion and the lower skin portion. The multi-spar element may be attached to the upper skin portion and the lower skin portion.

Abstract: In one aspect, there is a joint member for a composite having a laminate layer including a support member having a first side and a second side; a first flange extending laterally from the first side and having an attachment surface for attachment to a structure; and a second flange extending laterally from the second side and having an attachment surface configured for attachment to the laminate layer. The joint member is configured to provide a load path from the first flange to the second flange. In an embodiment, a joint system for a composite system includes a joint member attached to a first skin and a second skin. In still another embodiment, a joint system for a rib assembly includes a joint member attached to a rib web and rib post.

Abstract: In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the mold, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the mold. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the mold, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies.