Abstract: A defect visualization system includes an augmented reality viewing device including a display, and a visualization module configured to receive defect data representative of the defects on the part, determine a position of the augmented reality viewing device in relation to the part, generate one or more display objects, wherein each display object of the display objects corresponds to a respective defect of the defects, and present the display objects on the display so that the display objects appear in alignment with the defects on the part.

Abstract: A surface analyst end effector for an automated inspection and repair system for composite parts. A surface analyst system and a tool changer are supported on a chassis. A control unit of the surface analyst system is configured to conduct a bond readiness test by which the control unit directs an inspection head to place a drop of liquid onto a surface of a composite part and directs the inspection head to capture an image of the drop on the surface. The slave tool changer releasably and operatively connects the end effector to an industrial robot such that the industrial robot can move the end effector along the composite part and the inspection and repair system can signal the surface analyst to conduct a bond readiness test. The surface analyst end effector is interchangeable with other end effectors of the inspection and repair system for performing inspection and repair methods.

Abstract: An induction welder for inductively welding two or more components has an induction coil for applying a magnetic field to a weld site of the two or more components to inductively weld the two or more components together. The induction coil includes a proximal end and a distal end. The distal end is positioned proximate the weld site of the two or more components to inductively weld the two or more components at the weld site. A press is disposed distally of the induction coil such that the press is disposed between the induction coil and the two or more components when the two or more components are being inductively welded together. The press is used to apply pressure to the two or more components and press the two or more components together at the weld site simultaneously with the application of the magnetic field at the weld site.

Abstract: A composite window plug can be used to plug a window frame in an aircraft, for example, during aircraft conversion and modification services. The composite window plug is formed from a stamped composite laminate and an over-molded rib structure fused to the interior surface of the stamped composite laminate. The over-molded rib structure has multiple ribs extending inwards from a perimeter rib to form a stiffening pattern. The stamped composite and the over-molded rib structure may include a thermoplastic material reinforced with fibers. The composite window plug can be formed in a stamping and over-molding process conducted in a single mold.

Abstract: In a method of visualizing one or more defects on a part comprises, defect data representative of the one or more defects on the part is obtained by an in-process automated fiber placement manufacturing inspection system. The data is then received by a visualization module. A location on the part is determined for each defect of the one or more defects. One or more laser lines are projected onto the part to indicate the location of at least one defect of the one or more defects. The method can be implemented by a system that uses a laser projection system to project the laser lines on the part and a user device running a visualization app that interfaces with the main software for the in-process automated fiber placement manufacturing inspection system.

Abstract: In a method of using ultrasonic welding for fusion bonding of thermoplastic composites, an energy director is formed in place on a first thermoplastic substrate. The energy director can be protrusions arranged in a grid pattern over the entire weld region. The energy director can have protrusions of varying thicknesses to account for unevenness along the weld interface. Forming the energy director can be carried out by placing thermoplastic film on the first thermoplastic substrate, melting the thermoplastic film, and stamping the thermoplastic film with an energy director stamp. After the energy director is formed, the first thermoplastic substrate is ultrasonically welded to a second thermoplastic substrate with the energy director sandwiched between the first and second thermoplastic substrates.

Abstract: A laser shearography end effector for inspection in an automated inspection and repair system for composite parts. A laser shearography system including an excitation system and a laser shearography camera is supported on a frame for movement with the frame. A slave tool changer is secured to the frame for releasably and operatively connecting the inspection tool to an industrial robot such that the industrial robot can move the inspection tool along a work piece as the laser shearography system inspects the work piece and such that the laser shearography end effector is interchangeable with at least one other automatic inspection end effector or repair end effector of the automated inspection and repair system.

Abstract: A robot end effector for surface preparation in an automated inspection and repair system for composite parts has an end effector body and a plasma control unit and a plasma jet nozzle supported on the end effector body. The plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle. A slave tool changer is secured to the end effector body. The slave tool changer releasably and operatively connects the robot end effector to an industrial robot such that the industrial robot can move the robot end effector along a composite part as the plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle toward the composite part to clean the composite part and increase a surface free energy of the composite part.

Abstract: A defect visualization system includes an augmented reality viewing device including a display, and a visualization module configured to receive defect data representative of the defects on the part, determine a position of the augmented reality viewing device in relation to the part, generate one or more display objects, wherein each display object of the display objects corresponds to a respective defect of the defects, and present the display objects on the display so that the display objects appear in alignment with the defects on the part.

Abstract: An augmented reality visualization system is disclosed for viewing non-destructive inspection (NDI) data of a component. The system comprises a component camera configured to capture a real time image of the component, a component display configured to display an AR image of the component, and an AR controller including an augmented reality processor and a non-transitory tangible storage medium. The storage medium includes processor-executable instructions for controlling the AR processor when the instructions are executed by the AR processor. The instructions access the NDI data of the component and implement a component AR engine to generate the AR image in real time by overlaying the NDI data on the real time image. The AR engine is configured to detect one or more three-dimensional (3D) features of the component in the real-time image and generate the AR image based on the detected one or more features.

Abstract: A laser shearography end effector for inspection in an automated inspection and repair system for composite parts. A laser shearography system including an excitation system and a laser shearography camera is supported on a frame for movement with the frame. A slave tool changer is secured to the frame for releasably and operatively connecting the inspection tool to an industrial robot such that the industrial robot can move the inspection tool along a work piece as the laser shearography system inspects the work piece and such that the laser shearography end effector is interchangeable with at least one other automatic inspection end effector or repair end effector of the automated inspection and repair system.

Abstract: A robot end effector for surface preparation in an automated inspection and repair system for composite parts has an end effector body and a plasma control unit and a plasma jet nozzle supported on the end effector body. The plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle. A slave tool changer is secured to the end effector body. The slave tool changer releasably and operatively connects the robot end effector to an industrial robot such that the industrial robot can move the robot end effector along a composite part as the plasma control unit directs a jet of atmospheric plasma through the plasma jet nozzle toward the composite part to clean the composite part and increase a surface free energy of the composite part.

Abstract: A system for digitally processing cash transaction between a vendor using a vendor device and a consumer using a consumer device, wherein the transaction comprises a transaction amount and a cash amount greater than the transaction amount defining a change amount that can be the difference between the cash amount and the transaction amount. The system comprising an accounting platform on a system device comprising at least one vendor account. A vendor application program on the vendor device associated with the at least one vendor profile and comprising a vendor interface, wherein the vendor can add money to the vendor account. A processor on the system device that credits and debits vendor accounts and consumer accounts and in response to requests received from at least one of the vendor application program.

Abstract: A surface analyst end effector for an automated inspection and repair system for composite parts. A surface analyst system and a tool changer are supported on a chassis. A control unit of the surface analyst system is configured to conduct a bond readiness test by which the control unit directs an inspection head to place a drop of liquid onto a surface of a composite part and directs the inspection head to capture an image of the drop on the surface. The slave tool changer releasably and operatively connects the end effector to an industrial robot such that the industrial robot can move the end effector along the composite part and the inspection and repair system can signal the surface analyst to conduct a bond readiness test. The surface analyst end effector is interchangeable with other end effectors of the inspection and repair system for performing inspection and repair methods.

Abstract: An augmented reality visualization system is disclosed for viewing non-destructive inspection (NDI) data of a component. The system comprises a component camera configured to capture a real time image of the component, a component display configured to display an AR image of the component, and an AR controller including an augmented reality processor and a non-transitory tangible storage medium. The storage medium includes processor-executable instructions for controlling the AR processor when the instructions are executed by the AR processor. The instructions access the NDI data of the component and implement a component AR engine to generate the AR image in real time by overlaying the NDI data on the real time image. The AR engine is configured to detect one or more three-dimensional (3D) features of the component in the real-time image and generate the AR image based on the detected one or more features.

Abstract: An induction welder for inductively welding two or more components has an induction coil for applying a magnetic field to a weld site of the two or more components to inductively weld the two or more components together. The induction coil includes a proximal end and a distal end. The distal end is positioned proximate the weld site of the two or more components to inductively weld the two or more components at the weld site. A press is disposed distally of the induction coil such that the press is disposed between the induction coil and the two or more components when the two or more components are being inductively welded together. The press is used to apply pressure to the two or more components and press the two or more components together at the weld site simultaneously with the application of the magnetic field at the weld site.

Abstract: A system for generating a repair patch for a damaged area of a composite structure may include a scanning module, a repair patch model generator and a cutting tool. The scanning module may be deployed at the location of the damaged composite structure. The scanning module may be configured to scan the damaged area to generate scanned data indicative of a shape, size and/or contours of the damaged area. The repair patch model generator may include processing circuitry configured to obtain the scanned data, obtain parent ply information of the damaged composite structure, and generating a patch model of a repair patch including size and shape definition for each of a plurality of plies based on the scanned data and the parent ply information. The cutting tool may be configured to receive cutting files based on the patch model to generate a plurality of cut plies that combine to form the repair patch.

Abstract: A system for generating a repair patch for a damaged area of a composite structure may include a scanning module, a repair patch model generator and a cutting tool. The scanning module may be deployed at the location of the damaged composite structure. The scanning module may be configured to scan the damaged area to generate scanned data indicative of a shape, size and/or contours of the damaged area. The repair patch model generator may include processing circuitry configured to obtain the scanned data, obtain parent ply information of the damaged composite structure, and generating a patch model of a repair patch including size and shape definition for each of a plurality of plies based on the scanned data and the parent ply information. The cutting tool may be configured to receive cutting files based on the patch model to generate a plurality of cut plies that combine to form the repair patch.