Abstract: A method and apparatus are used to form a corrugated web having a cross sectional shape with at least one characteristic that varies substantially continuously along the substantially the entire length of the web. The apparatus includes multiple sets of dies which progressively form corrugations in a moving sheet. At least one characteristic of the web's cross sectional shape is varied along the entire length of the web by displacing the dies as the sheet moves through the die sets.

Abstract: The structural strength of an aircraft wing is continuously tailored along its length to closely match continuously varying imposed wing loads. The wing includes upper and lower skins each formed from panels joined together. Each of the skin panels includes a stiffening web sandwiched between and joined to the inner and outer facesheets. The web has a repeating pattern and at least one dimension that continuously varies along the length of the panel.

Abstract: Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes a tool surface configured to support fiber-reinforced resin material and define an outer mold line (OML) of the fiber-reinforced resin material. The movable support system is configured to respond to signals from a controller to automatically change the shape of the tool surface and alter the OML of the finished part to suit the particular application. In one embodiment, the movable support system can include a plurality of telescoping actuators operably coupled to the tool plate.

Abstract: A method and apparatus are used to form a corrugated web having a cross sectional shape with at least one characteristic that varies substantially continuously along the substantially the entire length of the web. The apparatus includes multiple sets of dies which progressively form corrugations in a moving sheet. At least one characteristic of the web's cross sectional shape is varied along the entire length of the web by displacing the dies as the sheet moves through the die sets.

Abstract: The structural strength of an aircraft wing is continuously tailored along its length to closely match continuously varying imposed wing loads. The wing comprises upper and lower skins each formed from panels joined together. Each of the skin panels includes a stiffening web sandwiched between and joined to the inner and outer facesheets. The web has a repeating pattern and at least one dimension that continuously varies along the length of the panel.

Abstract: Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes a tool surface configured to support fiber-reinforced resin material and define an outer mold line (OML) of the fiber-reinforced resin material. The movable support system is configured to respond to signals from a controller to automatically change the shape of the tool surface and alter the OML of the finished part to suit the particular application. In one embodiment, the movable support system can include a plurality of telescoping actuators operably coupled to the tool plate.

Abstract: Methods and systems for manufacturing composite aircraft wings and other structures are disclosed herein. A tool assembly for use in manufacturing composite laminates in accordance with one embodiment of the invention includes a tool plate carried by a movable support system. The tool plate includes a tool surface configured to support fiber-reinforced resin material and define an outer mold line (OML) of the fiber-reinforced resin material. The movable support system is configured to respond to signals from a controller to automatically change the shape of the tool surface and alter the OML of the finished part to suit the particular application. In one embodiment, the movable support system can include a plurality of telescoping actuators operably coupled to the tool plate.

Abstract: An apparatus and method for forming corrugated contours in a sheet are provided. The apparatus includes at least three pairs of elongate dies that extend in a longitudinal direction. Each pair of dies is generally parallel and defines a nip therebetween so that the sheet can be moved successively through the nips. At least one actuator is configured to actuate each pair of dies in successively opposed directions generally perpendicular to a direction of motion of the sheet to thereby form the contours in the sheet. Further, each pair of dies is adjustable in a transverse direction generally parallel to the direction of motion of the sheet so that an offset distance between each successive pair of dies can be adjusted.

Abstract: An apparatus and method for forming corrugated contours in a sheet are provided. The apparatus includes at least three pairs of elongate dies that extend in a longitudinal direction. Each pair of dies is generally parallel and defines a nip therebetween so that the sheet can be moved successively through the nips. At least one actuator is configured to actuate each pair of dies in successively opposed directions generally perpendicular to a direction of motion of the sheet to thereby form the contours in the sheet. Further, each pair of dies is adjustable in a transverse direction generally parallel to the direction of motion of the sheet so that an offset distance between each successive pair of dies can be adjusted.