Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

Abstract: A composite wall assembly edge joint, includes a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet. The assembly further includes a composite flute core member, having a tapered first portion secured to the first tapered section; a second portion secured to the first composite face sheet; and a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section.

Abstract: A composite wall assembly edge joint, includes a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet. The assembly further includes a composite flute core member, having a tapered first portion secured to the first tapered section; a second portion secured to the first composite face sheet; and a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section.

Abstract: A radius filler for a composite assembly may include a pair of vertical ply stacks positioned in back-to-back relation. Each one of the vertical ply stacks may be formed of one or more thick plies of composite material formed in an L-shaped cross-section having a vertical leg and a lateral leg interconnected by a stack radius and defining a crescent region. At least one of the crescent regions may include one or more thin plies of composite material positioned adjacent to a stack radius inner surface. Each one of the thin plies may have a ply thickness that is less than the ply thickness of the thick plies.