Abstract: A breather used for vacuum bag compaction of a composite laminate part is semi-permanently installed on a compaction tool. The breather is a channel member having an internal passageway that routes air and volatiles from the vacuum bag to a vacuum port in the tool.

Abstract: Forming systems and methods for forming an elongate charge of composite material are disclosed herein. The forming systems include an elongate forming tool having an elongate forming surface with a forming surface shape that corresponds to a predetermined material shape for the elongate charge of composite material. The forming systems also include an elongate end effector, which is configured to tension the elongate charge of composite material across the forming surface. The elongate end effector includes an elongate vacuum distribution manifold, a porous elongate vacuum region, and an elongate friction surface. The methods include methods of tensioning an elongate charge of composite material across an elongate forming surface of an elongate forming tool utilizing an elongate end effector.

Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Abstract: A composite structure including a multi-layer laminate having a plurality of regions each oriented out of plane relative to an adjacent region, and each extending in a longitudinal dimension of the multi-layer laminate, wherein the multi-layer laminate includes at least one ply layer having an oblique fiber orientation relative to the longitudinal dimension, and wherein the at least one ply layer includes a first section and a second section each having a side edge, the first and second sections aligned side-by-side such that a first interface defined between the respective side edges is oriented to extend in the longitudinal dimension.

Abstract: Forming systems and methods for forming an elongate charge of composite material are disclosed herein. The forming systems include an elongate forming tool having an elongate forming surface with a forming surface shape that corresponds to a predetermined material shape for the elongate charge of composite material. The forming systems also include an elongate end effector, which is configured to tension the elongate charge of composite material across the forming surface. The elongate end effector includes an elongate vacuum distribution manifold, a porous elongate vacuum region, and an elongate friction surface. The methods include methods of tensioning an elongate charge of composite material across an elongate forming surface of an elongate forming tool utilizing an elongate end effector.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.

Abstract: A composite structure including a multi-layer laminate having a plurality of regions each oriented out of plane relative to an adjacent region, and each extending in a longitudinal dimension of the multi-layer laminate, wherein the multi-layer laminate includes at least one ply layer having an oblique fiber orientation relative to the longitudinal dimension, and wherein the at least one ply layer includes a first section and a second section each having a side edge, the first and second sections aligned side-by-side such that a first interface defined between the respective side edges is oriented to extend in the longitudinal dimension.

Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Abstract: A composite manufacturing system for aircraft structures is provided. The composite manufacturing system comprises a tool for forming a composite structure, a vacuum bag, and a tool base. The tool comprises cured composite planks and layers of flexible material. The cured composite planks run parallel to each other. The layers of flexible material are positioned between and bonded to the cured composite planks. The vacuum bag surrounds the tool and is configured to apply pressure to the tool during curing of the composite structure. The tool is configured to deform in response to the pressure and prevent poor quality laminate and/or anomalies from developing in the composite structure during curing. The tool base is configured to hold the tool in place as it deforms.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.

Abstract: A composite manufacturing system for aircraft structures is provided. The composite manufacturing system comprises a tool for forming a composite structure, a vacuum bag, and a tool base. The tool comprises cured composite planks and layers of flexible material. The cured composite planks run parallel to each other. The layers of flexible material are positioned between and bonded to the cured composite planks. The vacuum bag surrounds the tool and is configured to apply pressure to the tool during curing of the composite structure. The tool is configured to deform in response to the pressure and prevent poor quality laminate and/or anomalies from developing in the composite structure during curing. The tool base is configured to hold the tool in place as it deforms.

Abstract: Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

Abstract: A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.