Abstract: A method for pelletizing an extruded material with an extruding nozzle includes inserting the extruded material into the extruding nozzle so that the extruded material flows through at least one material-flow channel, extending through a radiator of the extruding nozzle. Heat is transferred between the extruded material, flowing through the at least one material-flow channel, and the radiator. At least a portion of the radiator is located within a housing of the extruding nozzle.

Abstract: Heating apparatus and methods for thermally processing a part including improved control of temperature. A thermal management system is coupled to a back surface of a table thermally coupled to an inductive heating circuit. The thermal management system includes a chamber defining an interior space, at least one cooling fin disposed within the chamber, an inlet extending through the chamber and fluidly communicating with the interior space, and an outlet extending through the chamber and fluidly communicating with the interior space. In some applications, an air source fluidly communicates with the inlet and is selectively operable to generate an air flow through the chamber, so that the thermal management system may be selectively operated in an insulator mode and a cooling mode.

Abstract: A multi-axis gantry system comprising a multi-axis gantry apparatus and vacuum system, and method for repositioning is disclosed. The multi-axis gantry system comprises a frame. The frame includes a plurality of curved base members, a first rail, a second rail, a bridge slidably moveable along the first rail and the second rail, a carriage including an end effector, and a first plurality of pucks and a second plurality of pucks. The vacuum system comprises a vacuum controller, a first vacuum source and a second vacuum source. Each of the first and second vacuum sources is in fluid communication with one or more pucks of the first and second pluralities of pucks. The frame is reconfigurable from a first configuration mountable on a first work surface to a second configuration mountable on a second work surface that may be different from the first work surface.

Abstract: Heating apparatus and methods for forming a part with a non-planar shape include a table formed of a thermally conductive material and defining a table surface. A tool, also formed of a thermally conductive material, has a base surface configured to engage the table surface of the table and a tooling surface opposite the base surface, wherein the tooling surface has a contoured shape that is non-planar. A heating blanket is provided above the table and defines a heating surface. The tooling surface of the tool is configured to engage a first surface of the part and the heating surface of the heating blanket is configured to engage a second surface of the part opposite the first surface of the part. The table and the heating blanket are heated to a processing temperature so that the part at least partially conforms to the tooling surface of the tool.

Abstract: A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Abstract: A multi-axis gantry system comprising a multi-axis gantry apparatus and vacuum system, and method for repositioning is disclosed. The multi-axis gantry system comprises a frame. The frame includes a plurality of curved base members, a first rail, a second rail, a bridge slidably moveable along the first rail and the second rail, a carriage including an end effector, and a first plurality of pucks and a second plurality of pucks. The vacuum system comprises a vacuum controller, a first vacuum source and a second vacuum source. Each of the first and second vacuum sources is in fluid communication with one or more pucks of the first and second pluralities of pucks. The frame is reconfigurable from a first configuration mountable on a first work surface to a second configuration mountable on a second work surface that may be different from the first work surface.

Abstract: A method for pelletizing an extruded material with an extruding nozzle includes inserting the extruded material into the extruding nozzle so that the extruded material flows through at least one material-flow channel, extending through a radiator of the extruding nozzle. Heat is transferred between the extruded material, flowing through the at least one material-flow channel, and the radiator. At least a portion of the radiator is located within a housing of the extruding nozzle.

Abstract: Apparatus including a robotically controlled end effector having a compliant nosepiece that forms plies of a material onto contoured surfaces of a tool. The end effector includes a plurality of individually controllable rotary actuators which respectively control the position and compliancy of individual sections of the nosepiece in order to better conform the plies the contoured tool surfaces.

Abstract: An extruding nozzle is provided. The extruding nozzle includes a housing and a radiator. The radiator is at least partially disposed within the housing. The extruding nozzle also includes at least one material flow channel. The at least one material flow channel is at least partially disposed within the housing and extends through the radiator.

Abstract: A tooling assembly is provided, for use with a panel defining a tool-side surface and the tool-side surface defining a profile. The tooling assembly includes a base, a plurality of support members fixedly attached to the base, a plurality of frames, and a securing system. The frames each define an upper surface, where each support member is releasably coupled to a corresponding frame by a fastening system. The upper surfaces of the frames are each shaped to correspond with a portion of the profile of the tool-side surface of the panel. The securing system is for providing a suction force configured to releasably secure the panel against the upper surface of the frames.

Abstract: A nozzle for extruding a composite material from an extruder barrel. The nozzle includes a body and a tapered nozzle passage extending through the body. The tapered nozzle passage having a nozzle inlet opening configured to interface with the extruder barrel, and a nozzle outlet opening, where the tapered nozzle passage has a contoured nozzle passage surface extending between the extruder barrel and the nozzle outlet opening with smooth transitions, free of angles, so that each nozzle passage surface portion, having a corresponding contour, transitions smoothly to each other nozzle passage surface portion, having a respective different contour, from the nozzle inlet opening to the nozzle outlet opening, and the nozzle outlet opening is defined by at least a first edge and a second edge that intersect each other at an acute angle.

Abstract: Systems and methods are provided for automatic tool loading of a milling machine. One embodiment is an apparatus for loading tools into a milling machine. The apparatus includes a base platform configured to rest on a table of the milling machine, and a support column extending vertically from the base platform. The apparatus also includes a holding member slidably coupled with the support column above the base platform, the holding member extending horizontally from the support column and configured to translate vertically along the support column, and to support a tool holder in an upright position for loading the tool holder into a spindle of the milling machine.

Abstract: An installation tool and method are provided to apply a patch to a structure while controlling the porosity in the bond line. An installation tool is provided that includes a frame defining an internal cavity. The installation tool also includes a flexible membrane that divides the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane. The flexible membrane is releasably attached to the patch such that the patch faces the surface. The frame includes first and second vacuum ports into the first and second chambers, respectively, such that pressure therewithin is separately controllable. The pressure within the first and second chambers is controlled such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched to urge the patch toward the surface.

Abstract: Heating apparatus and methods for thermally processing a part including improved control of temperature. A thermal management system is coupled to a back surface of a table thermally coupled to an inductive heating circuit. The thermal management system includes a chamber defining an interior space, at least one cooling fin disposed within the chamber, an inlet extending through the chamber and fluidly communicating with the interior space, and an outlet extending through the chamber and fluidly communicating with the interior space. In some applications, an air source fluidly communicates with the inlet and is selectively operable to generate an air flow through the chamber, so that the thermal management system may be selectively operated in an insulator mode and a cooling mode.

Abstract: Heating apparatus and methods for forming a part with a non-planar shape include a table formed of a thermally conductive material and defining a table surface. A tool, also formed of a thermally conductive material, has a base surface configured to engage the table surface of the table and a tooling surface opposite the base surface, wherein the tooling surface has a contoured shape that is non-planar. A heating blanket is provided above the table and defines a heating surface. The tooling surface of the tool is configured to engage a first surface of the part and the heating surface of the heating blanket is configured to engage a second surface of the part opposite the first surface of the part. The table and the heating blanket are heated to a processing temperature so that the part at least partially conforms to the tooling surface of the tool.

Abstract: An extruding nozzle is provided. The extruding nozzle includes a housing and a radiator. The radiator is at least partially disposed within the housing. The extruding nozzle also includes at least one material flow channel. The at least one material flow channel is at least partially disposed within the housing and extends through the radiator.

Abstract: Apparatus including a robotically controlled end effector having a compliant nosepiece that forms plies of a material onto contoured surfaces of a tool. The end effector includes a plurality of individually controllable rotary actuators which respectively control the position and compliancy of individual sections of the nosepiece in order to better conform the plies the contoured tool surfaces.

Abstract: A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Abstract: An applicator assembly for treating a contoured surface including an attachment frame configured to secure and position an applicator head. In some embodiments, the applicator head is configured to apply a surface treatment to the contoured surface. The applicator assembly further includes, at least one sensor operatively coupled to the attachment frame and configured to scan the contoured surface and produce a contoured data set. Additionally, the applicator assembly includes an applicator actuator operatively coupled to the attachment frame and configured to manipulate the attachment frame such that the applicator assembly maintains an orientation of the applicator assembly relative to the contoured surface.

Abstract: An installation tool and method are provided to apply a patch to a structure while controlling the porosity in the bond line. An installation tool is provided that includes a frame defining an internal cavity. The installation tool also includes a flexible membrane that divides the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane. The flexible membrane is releasably attached to the patch such that the patch faces the surface. The frame includes first and second vacuum ports into the first and second chambers, respectively, such that pressure therewithin is separately controllable. The pressure within the first and second chambers is controlled such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched to urge the patch toward the surface.