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 and a collapsible support having a support surface. The collapsible support is configured to transition from an extended conformation to a collapsed conformation and is configured such that a gap width of a gap between the support surface and the forming surface decreases during the transition. The methods include positioning a composite charge, transitioning the collapsible support from an extended conformation to a collapsed conformation, decreasing the gap width of the gap as the collapsible support transitions from the extended conformation to the collapsed conformation, and deforming the composite charge from an initial conformation to a final conformation.

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 and a collapsible support having a support surface. The collapsible support is configured to transition from an extended conformation to a collapsed conformation and is configured such that a gap width of a gap between the support surface and the forming surface decreases during the transition. The methods include positioning a composite charge, transitioning the collapsible support from an extended conformation to a collapsed conformation, decreasing the gap width of the gap as the collapsible support transitions from the extended conformation to the collapsed conformation, and deforming the composite charge from an initial conformation to a final conformation.

Abstract: Radius fillers for composite structures and composite structures that include radius fillers are disclosed herein. The radius fillers include a plurality of lengths of composite tape. Each of the plurality of lengths of composite tape includes a respective plurality of lengths of reinforcing fibers and a resin material. The plurality of lengths of reinforcing fibers in each of the plurality of lengths of composite tape defines a fiber axis direction. Each of the plurality of lengths of composite tape defines a respective fiber axis direction that is based, at least in part, on material properties of a transition region defined by a plurality of plies of composite material that defines an elongate void space within which the radius filler is configured to extend. The composite structures include the radius fillers.

Abstract: Radius fillers for composite structures and composite structures that include radius fillers are disclosed herein. The radius fillers include a plurality of lengths of composite tape. Each of the plurality of lengths of composite tape includes a respective plurality of lengths of reinforcing fibers and a resin material. The plurality of lengths of reinforcing fibers in each of the plurality of lengths of composite tape defines a fiber axis direction. Each of the plurality of lengths of composite tape defines a respective fiber axis direction that is based, at least in part, on material properties of a transition region defined by a plurality of plies of composite material that defines an elongate void space within which the radius filler is configured to extend. The composite structures include the radius fillers.

Abstract: Radius fillers for composite structures, composite structures that include radius fillers, and systems and methods of forming the same are disclosed herein. The methods include determining a transverse cross-sectional shape of an elongate void space, which extends within a transition region that is defined by a plurality of plies of composite material, and determining a material property field of the transition region. The methods further include forming the radius filler by combining a plurality of lengths of composite tape to define a radius filler cross-sectional shape, which corresponds to the transverse cross-sectional shape of the elongate void space, and orienting a plurality of lengths of reinforcing fiber in each of the plurality of lengths of composite tape based, at least in part, on the material property field of the transition region. The radius fillers include radius fillers with selectively oriented reinforcing fibers. The composite structures include the radius fillers.

Abstract: Radius fillers for composite structures, composite structures that include radius fillers, and systems and methods of forming the same are disclosed herein. The methods include determining a transverse cross-sectional shape of an elongate void space, which extends within a transition region that is defined by a plurality of plies of composite material, and determining a material property field of the transition region. The methods further include forming the radius filler by combining a plurality of lengths of composite tape to define a radius filler cross-sectional shape, which corresponds to the transverse cross-sectional shape of the elongate void space, and orienting a plurality of lengths of reinforcing fiber in each of the plurality of lengths of composite tape based, at least in part, on the material property field of the transition region. The radius fillers include radius fillers with selectively oriented reinforcing fibers. The composite structures include the radius fillers.