Abstract: A pick and place end effector configured to form a kink in a composite laminate. The pick and place end effector comprises a vacuum lift face configured to hold the composite laminate and move from a flat configuration to a forming configuration with an angle in the vacuum lift face to form the kink in the composite laminate; a number of motors configured to move the vacuum lift face between the flat configuration and the forming configuration; and a number of restraints configured to clamp portions of a composite laminate on opposite sides of the kink on the vacuum lift face during movement between the flat configuration and the forming configuration.

Abstract: A forming end effector and methods of use are presented. Methods of forming a composite material onto a mandrel are presented. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector.

Abstract: A method of sealing a component assembly includes applying onto a first component a first sealant bead having, in a cross-sectional view, a first width and a first height, wherein the first width is greater than the first height. The method also includes applying over the first sealant bead a second sealant bead having, in the cross-sectional view, a second width and a second height, thereby generating a sealant stack. The second width is equal to or smaller than the second height and the second width is smaller than the first width. The method additionally includes arranging over the sealant stack a second component, such that the sealant stack is positioned between the first and second components. Furthermore, the method includes fastening the second component to the first component with the sealant stack squeezed therebetween to generate a fluid-tight seal via rheological flow of the first and second sealant beads.

Abstract: A method and a handling system for imparting a desired longitudinal conformation into a longitudinal component are presented. The handling system comprises a rigid frame and a plurality of handling headers movably connected to the rigid frame. The plurality of handling headers is configured to grip a longitudinal component, lift the longitudinal component, and cooperatively move to impart the desired longitudinal conformation into the longitudinal component.

Abstract: An ultrasonic injection device and methods of use are presented. The ultrasonic injection device comprises a housing, an injection nozzle attached to the housing, an ultrasonic vibration generator attached to the housing, and a pressure applicator. The injection nozzle has a number of openings configured to dispense a fluid. The ultrasonic vibration generator is configured to apply ultrasonic energy to fluid within the injection nozzle. The pressure application is configured to propel the fluid towards and out of the number of openings.

Abstract: A forming end effector and methods of use are presented. Methods of forming a composite material onto a mandrel are presented. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector.

Abstract: A method of sealing a component assembly includes applying onto a first component a first sealant bead having, in a cross-sectional view, a first width and a first height, wherein the first width is greater than the first height. The method also includes applying over the first sealant bead a second sealant bead having, in the cross-sectional view, a second width and a second height, thereby generating a sealant stack. The second width is equal to or smaller than the second height and the second width is smaller than the first width. The method additionally includes arranging over the sealant stack a second component, such that the sealant stack is positioned between the first and second components. Furthermore, the method includes fastening the second component to the first component with the sealant stack squeezed therebetween to generate a fluid-tight seal via rheological flow of the first and second sealant beads.

Abstract: A pick and place end effector configured to form a kink in a composite laminate. The pick and place end effector comprises a vacuum lift face configured to hold the composite laminate and move from a flat configuration to a forming configuration with an angle in the vacuum lift face to form the kink in the composite laminate; a number of motors configured to move the vacuum lift face between the flat configuration and the forming configuration; and a number of restraints configured to clamp portions of a composite laminate on opposite sides of the kink on the vacuum lift face during movement between the flat configuration and the forming configuration.

Abstract: Systems for forming composite parts, methods of forming composite parts, and methods of precisely performing a plurality of operations on a composite part. The systems include a layup mandrel that includes a mandrel body and a plurality of regions of isotropic surface finish. The methods of forming the composite part include positioning a plurality of plies of composite material on a layup mandrel, conforming the plurality of plies of composite material to a layup surface shape of the layup mandrel, and curing the plurality of plies of composite material. The methods of precisely performing the plurality of operations on a composite part include detecting a corresponding imprinted feature of a plurality of imprinted features, aligning an operating assembly of an end effector relative to the corresponding imprinted feature, and performing a corresponding operation of the plurality of operations on the composite part.

Abstract: A composite manufacturing system is provided. The composite manufacturing system comprises a robotic arm and a trimming and scrap removal system connected to the robotic arm. The trimming system and scrap removal comprises an ultrasonic knife, an ultrasonic parting horn, and a web support. The parting horn is configured to push scrap away from a trimmed part before the scrap has a chance to heat weld back to the trimmed part.

Abstract: An ultrasonic injection device and methods of use are presented. The ultrasonic injection device comprises a housing, an injection nozzle attached to the housing, an ultrasonic vibration generator attached to the housing, and a pressure applicator. The injection nozzle has a number of openings configured to dispense a fluid. The ultrasonic vibration generator is configured to apply ultrasonic energy to fluid within the injection nozzle. The pressure application is configured to propel the fluid towards and out of the number of openings.

Abstract: Systems for forming composite parts, methods of forming composite parts, and methods of precisely performing a plurality of operations on a composite part. The systems include a layup mandrel that includes a mandrel body and a plurality of regions of isotropic surface finish. The methods of forming the composite part include positioning a plurality of plies of composite material on a layup mandrel, conforming the plurality of plies of composite material to a layup surface shape of the layup mandrel, and curing the plurality of plies of composite material. The methods of precisely performing the plurality of operations on a composite part include detecting a corresponding imprinted feature of a plurality of imprinted features, aligning an operating assembly of an end effector relative to the corresponding imprinted feature, and performing a corresponding operation of the plurality of operations on the composite part.

Abstract: The magnetic handling systems comprise a bladder and a magnetic carriage system. The bladder is configured to be received within a stringer interior volume of a hat stringer and comprises a magnetic insert having a plurality of magnetic walls, each configured to align with a respective wall portion of the hat stringer. The magnetic carriage system comprises a carriage having a magnetic head that comprises a bracket and a plurality of magnetic sources supported by the bracket. Each magnetic source is configured to magnetically couple with a respective magnetic wall of the magnetic insert to produce an attractive magnetic force therebetween. The methods comprise disposing a bladder having a plurality of the magnetic inserts within the hat stringer, magnetically engaging a plurality of the magnetic heads with the plurality of magnetic inserts, and conforming the hat stringer by moving at least one magnetic head relative to another magnetic head.

Abstract: A stiffener composite charge placement system is presented. The stiffener composite charge placement system comprises a longitudinal end effector having a first attachment point and a second attachment point; a first rotational arm having a first connector configured to connect to the first attachment point; a first movement system configured to move the first rotational arm within a manufacturing environment; a second rotational arm having a second connector configured to connect to the second attachment point; and a second movement system configured to move the second rotational arm within the manufacturing environment.

Abstract: A composite manufacturing system is provided. The composite manufacturing system comprises a robotic arm and a trimming system connected to the robotic arm. The trimming system comprises a knife, a rotation device, a number of lasers, and a load cell associated with the knife. The rotation device is configured to rotate a blade of the knife about a center point. The number of lasers is configured to determine a position of the blade relative to a desired position for the blade. The load cell is configured to sense an amount of force applied to the blade during trimming of an uncured composite structure. A controller controls the behavior of the trimming system based on information received from its components.

Abstract: A stiffener composite charge placement system is presented. The stiffener composite charge placement system comprises a longitudinal end effector having a first attachment point and a second attachment point; a first rotational arm having a first connector configured to connect to the first attachment point; a first movement system configured to move the first rotational arm within a manufacturing environment; a second rotational arm having a second connector configured to connect to the second attachment point; and a second movement system configured to move the second rotational arm within the manufacturing environment.