Abstract: A manufacturing system includes a plurality of lamination heads and a head-moving system defining a continuous loop lamination path configured to move the lamination heads in series along the lamination path. The manufacturing system also includes at least one lamination mandrel positioned along a portion of the lamination path. The lamination heads are each configured to dispense a layup material onto the at least one lamination mandrel or onto layup material previously applied onto the lamination mandrel while the lamination heads are moved by the head-moving system through one or more revolutions of the lamination path to lay up a composite laminate.

Abstract: A lamination head has a material supply drum, a backing layer collection drum, and a backing layer separation assembly. The material supply drum supports a material roll of backed material comprising layup material backed by a backing layer. The backing layer collection drum moves from a collection drum home position to a collection drum engagement position proximate the material supply drum, engage a backing layer leading edge on the material roll, and moves back to the collection drum home position while dispensing a threadable portion of at least the backing layer. The backing layer separation assembly has a backing layer separation device and a backing layer separation mechanism. The backing layer separation device translates from a separation device home position to a separation device engagement position and pulls the threadable portion into proximity to the backing layer separation mechanism for separating the backing layer from the layup material.

Abstract: A lamination head having bi-directional layup capability has a material supply drum configured to support a material roll of backed material which is comprised of layup material backed by a backing layer. A backing layer separation assembly receives the backed material from the material supply drum and has a backing layer directional control device and first and second backing layer separation mechanisms. The backing layer directional control device in the first mode separation position is aligned with the first backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a first direction of travel. The backing layer directional control device in the second mode separation position is aligned with the second backing layer separation mechanism for separating the backing layer from the layup material as the lamination head moves along a second direction of travel.

Abstract: A manufacturing system includes a first mandrel, a second mandrel, and laminate securing mechanisms. The first mandrel has a first mandrel surface and a first mandrel surface edge. The second mandrel has a second mandrel surface and a second mandrel surface edge, and is positionable in a closed position in which the first mandrel surface edge and the second mandrel surface edge are in contact to form a continuous mandrel surface collectively defined by the first mandrel surface and the second mandrel surface. The second mandrel translates to an open position defining a gap between the first mandrel surface edge and the second mandrel surface edge for receiving a forming die. The laminate securing mechanisms secure the composite laminate on at least one of the first mandrel and the second mandrel during trimming and/or forming of the composite laminate.

Abstract: A method for fabricating a composite structure. A first section for the composite structure is formed in which the first section has a first end with a chevron shape, wherein first composite layers in the first section has a first step pattern at the first end. A second section for the composite structure is formed in which the second section has a second end with a counterpart shape to the chevron shape and in which second composite layers in the second section have a second step pattern at the second end. The first end the second end are positioned such that a first composite layer in the first composite layers in the first step pattern overlap the second composite layers in the second step pattern at a splice location.

Abstract: A plurality of segments of radius filler is positioned onto a radius filler forming tool. The plurality of segments of radius filler is applied to a stringer in a single placement step.

Abstract: A method for determining and verifying ply orientation of composite laminates includes performing a first scan of a prepared edge of a composite laminate using an off-axis inclined light source directing light at a first acute angle to a first area on the prepared edge to produce a first scanned image; rotating an orientation of the off-axis inclined light source relative to the prepared edge, such that the off-axis inclined light source directs light at a second acute angle symmetrically opposite the first acute angle; and performing a second scan of the prepared edge using the off-axis inclined light source directing light at the second acute angle to the first area on the prepared edge to produce a second scanned image. The method includes comparing the first and second scanned images to determine a ply orientation of each ply, and verifying the ply orientation against a baseline ply orientation.

Abstract: A method for determining and verifying ply orientation of composite laminates includes performing a first scan of a prepared edge of a composite laminate using an off-axis inclined light source directing light at a first acute angle to a first area on the prepared edge to produce a first scanned image; rotating an orientation of the off-axis inclined light source relative to the prepared edge, such that the off-axis inclined light source directs light at a second acute angle symmetrically opposite the first acute angle; and performing a second scan of the prepared edge using the off-axis inclined light source directing light at the second acute angle to the first area on the prepared edge to produce a second scanned image. The method includes comparing the first and second scanned images to determine a ply orientation of each ply, and verifying the ply orientation against a baseline ply orientation.

Abstract: A piezoelectric sensor having a plurality of electrodes deposited on a single surface of the dielectric medium is generally provided. The plurality of electrodes can define a plurality of square-shaped electrodes forming a grid on the first surface of the dielectric medium while the second electrode defines a continuous electrode. An electrode border surrounding the plurality of electrodes can be deposited on the first surface of the dielectric medium. Alternatively, the plurality of electrodes can define column-shaped electrodes, while the second electrode defines a plurality of row-shaped electrodes separated by etchings. The direction of orientation of each column-shaped electrode and the direction of orientation of each row-shaped electrode can be substantially perpendicular. A method of making a piezoelectric sensor is also provided.

Abstract: A piezoelectric sensor having a plurality of electrodes deposited on a single surface of the dielectric medium is generally provided. The plurality of electrodes can define a plurality of square-shaped electrodes forming a grid on the first surface of the dielectric medium while the second electrode defines a continuous electrode. An electrode border surrounding the plurality of electrodes can be deposited on the first surface of the dielectric medium. Alternatively, the plurality of electrodes can define column-shaped electrodes, while the second electrode defines a plurality of row-shaped electrodes separated by etchings. The direction of orientation of each column-shaped electrode and the direction of orientation of each row-shaped electrode can be substantially perpendicular. A method of making a piezoelectric sensor is also provided.