Abstract: A contoured composite laminate stiffener is fabricated by assembling a substantially flat composite laminate charge and forming the charge into a substantially straight stiffener having a desired cross sectional shape. A contour is formed in the stiffener which has an inside radius and an outside radius. Ply wrinkling is substantially eliminated by reducing compression strain on the inside radius as the stiffener as being contoured.

Abstract: Systems and methods for defining a surface contour of a layered charge of material are disclosed herein. The systems include a forming die, which includes a forming surface shaped to define a desired surface contour of the layered charge, and a fluidly actuated support, which includes a support surface that is adjacent to the forming surface and located to support the layered charge. The systems further include a vacuum bag that at least partially defines an enclosed volume and a vacuum source configured to selectively apply a vacuum to the enclosed volume. The methods include locating the layered charge on the forming surface and on the support surface, covering the layered charge with the vacuum bag to define the enclosed volume, applying the vacuum to the enclosed volume, compressing the fluidly actuated support, translating the support surface, and deforming the layered charge to define the desired surface contour.

Abstract: A gas containment apparatus for use with an end effector including at least one plasma head includes at least one enclosing structure coupled to the end effector. The enclosing structure is configured to capture a gas produced by the at least one plasma head. The gas containment apparatus also includes a duct coupled to the at least one enclosing structure and configured to channel the gas from within the enclosing structure.

Abstract: A contoured composite laminate stiffener is fabricated by assembling a substantially flat composite laminate charge and forming the charge into a substantially straight stiffener having a desired cross sectional shape. A contour is formed in the stiffener which has an inside radius and an outside radius. Ply wrinkling is substantially eliminated by reducing compression strain on the inside radius as the stiffener as being contoured.

Abstract: A gas containment apparatus for use with an end effector including at least one plasma head includes at least one enclosing structure coupled to the end effector. The enclosing structure is configured to capture a gas produced by the at least one plasma head. The gas containment apparatus also includes a duct coupled to the at least one enclosing structure and configured to channel the gas from within the enclosing structure.

Abstract: Systems and methods for compacting a charge of composite material. These systems and methods may utilize a vacuum compaction device to compact the charge of composite material on a supporting surface. The vacuum compaction device may be reusable and may be configured to define an enclosed volume when positioned on the supporting surface and may include a barrier structure and a sealing structure that is configured to form a fluid seal when compressed between the supporting surface and the barrier structure. The vacuum compaction device also may include a vacuum distribution manifold that is in fluid communication with and configured to selectively apply a vacuum to the enclosed volume. Application of the vacuum to the enclosed volume may decrease a pressure within the enclosed volume and transition the vacuum compaction device from an undeformed configuration to a deformed configuration, thereby compacting the charge of composite material on the supporting surface.

Abstract: Systems and methods for defining a surface contour of a layered charge of material are disclosed herein. The systems include a forming die, which includes a forming surface shaped to define a desired surface contour of the layered charge, and a fluidly actuated support, which includes a support surface that is adjacent to the forming surface and located to support the layered charge. The systems further include a vacuum bag that at least partially defines an enclosed volume and a vacuum source configured to selectively apply a vacuum to the enclosed volume. The methods include locating the layered charge on the forming surface and on the support surface, covering the layered charge with the vacuum bag to define the enclosed volume, applying the vacuum to the enclosed volume, compressing the fluidly actuated support, translating the support surface, and deforming the layered charge to define the desired surface contour.