Abstract: A forming system includes a femtosecond laser and a control unit that includes one or more processors operatively connected to the femtosecond laser. The femtosecond laser is configured to emit laser pulses onto an inner surface of a face sheet of an acoustic inner barrel. The acoustic inner barrel includes an acoustic core comprising an array of hexagonal cells attached to an outer surface of the face sheet that is opposite the inner surface. The control unit is configured to control the femtosecond laser to laser drill a plurality of perforations in the face sheet via emitting laser pulses at pulse durations between about 100 femtoseconds and about 10,000 femtoseconds and at frequencies over 100,000 Hz.

Abstract: A forming system includes a femtosecond laser and a control unit that includes one or more processors operatively connected to the femtosecond laser. The femtosecond laser is configured to emit laser pulses onto an inner surface of a face sheet of an acoustic inner barrel. The acoustic inner barrel includes an acoustic core comprising an array of hexagonal cells attached to an outer surface of the face sheet that is opposite the inner surface. The control unit is configured to control the femtosecond laser to laser drill a plurality of perforations in the face sheet via emitting laser pulses at pulse durations between about 100 femtoseconds and about 10,000 femtoseconds and at frequencies over 100,000 Hz such that the perforations are formed without burning portions of the face sheet or the acoustic core surrounding the perforations.

Abstract: A method and system for manufacturing a conical shaped acoustic structure. A sheet of acoustical material is cut to form individual pieces using a cutter system. Each individual piece in the individual pieces has a flat pattern for the conical shaped acoustic structure. An individual piece is positioned around a mandrel with a conical shape using an actuator system. Two edges of the individual piece are positioned for joining. The two edges of the individual piece positioned around the mandrel are joined to form the conical shaped acoustic structure.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: A forming system includes a femtosecond laser and a control unit that includes one or more processors operatively connected to the femtosecond laser. The femtosecond laser is configured to emit laser pulses onto an inner surface of a face sheet of an acoustic inner barrel. The acoustic inner barrel includes an acoustic core comprising an array of hexagonal cells attached to an outer surface of the face sheet that is opposite the inner surface. The control unit is configured to control the femtosecond laser to laser drill a plurality of perforations in the face sheet via emitting laser pulses at pulse durations between about 100 femtoseconds and about 10,000 femtoseconds and at frequencies over 100,000 Hz such that the perforations are formed without burning portions of the face sheet or the acoustic core surrounding the perforations.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: A method and system for manufacturing a conical shaped acoustic structure. A sheet of acoustical material is cut to form individual pieces using a cutter system. Each individual piece in the individual pieces has a flat pattern for the conical shaped acoustic structure. An individual piece is positioned around a mandrel with a conical shape using an actuator system. Two edges of the individual piece are positioned for joining. The two edges of the individual piece positioned around the mandrel are joined to form the conical shaped acoustic structure.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: A laser cuts overlapping ribbons of acoustic material into acoustic devices. An automatically controlled manipulator includes an end effector having groups of placement tools for simultaneously placing multiple acoustic devices in a cellular core. The placement tools include mandrels provided with vacuum pickups for picking up and holding the acoustic devices during transport to the core. A vision system aligns the placement tools with the cells of the core. The end effector includes a thermal radiation device for bonding the acoustic devices to the core.

Abstract: The present invention provides a solar tile and method for fabricating the same. The solar tile includes a flexible circuit having at least one electrically conductive path laminated between two insulating sheets. The flexible circuit includes a plurality of openings that are completely through the flexible circuit and define contact locations with the electrically conductive path. The solar tile also includes a plurality of coplanar photovoltaic solar cells that are secured to the flexible circuit so that the contacts are aligned with the openings in the flexible circuit. Further, the solar tile includes a plurality of electrically conductive solder connections located within the openings in the flexible circuit to electrically connect the solar cell contacts and the electrically conductive path. Additionally, in a preferred embodiment, the solar tile includes a single coverslide situated adjacent and covering the plurality of solar cells opposite the flexible circuit.

Abstract: The present invention provides a solar tile and method for fabricating the same. The solar tile includes a flexible circuit having at least one electrically conductive path laminated between two insulating sheets. The flexible circuit includes a plurality of openings that are completely through the flexible circuit and define contact locations with the electrically conductive path. The solar tile also includes a plurality of coplanar photovoltaic solar cells that are secured to the flexible circuit so that the contacts are aligned with the openings in the flexible circuit. Further, the solar tile includes a plurality of electrically conductive solder connections located within the openings in the flexible circuit to electrically connect the solar cell contacts and the electrically conductive path. Additionally, in a preferred embodiment, the solar tile includes a single coverslide situated adjacent and covering the plurality of solar cells opposite the flexible circuit.

Abstract: The present invention provides a solar tile and method for fabricating the same. The solar tile includes a flexible circuit having at least one electrically conductive path laminated between two insulating sheets. The flexible circuit includes a plurality of openings that are completely through the flexible circuit and define contact locations with the electrically conductive path. The solar tile also includes a plurality of coplanar photovoltaic solar cells that are secured to the flexible circuit so that the contacts are aligned with the openings in the flexible circuit. Further, the solar tile includes a plurality of electrically conductive solder connections located within the openings in the flexible circuit to electrically connect the solar cell contacts and the electrically conductive path. Additionally, in a preferred embodiment, the solar tile includes a single coverslide situated adjacent and covering the plurality of solar cells opposite the flexible circuit.

Abstract: The present invention provides a solar tile and method for fabricating the same. The solar tile includes a flexible circuit having at least one electrically conductive path laminated between two insulating sheets. The flexible circuit includes a plurality of openings that are completely through the flexible circuit and define contact locations with the electrically conductive path. The solar tile also includes a plurality of coplanar photovoltaic solar cells that are secured to the flexible circuit so that the contacts are aligned with the openings in the flexible circuit. Further, the solar tile includes a plurality of electrically conductive solder connections located within the openings in the flexible circuit to electrically connect the solar cell contacts and the electrically conductive path. Additionally, in a preferred embodiment, the solar tile includes a single coverslide situated adjacent and covering the plurality of solar cells opposite the flexible circuit.