Abstract: A method for forming a shaped composite structure. The method includes laying a composite laminate stack onto a mold, where the composite laminate stack comprises fabric laminate and resin and wherein the mold presents a predetermined shape, draping a vacuum film comprising polyethylene onto the composite laminate stack, thereby establishing an evacuatable volume between the vacuum film and the mold, applying suction to the evacuatable volume between the mold and the vacuum film to establish at least a partial vacuum within the evacuatable volume, thereby compressing the composite laminate stack via pressure applied to the vacuum film responsive to the at least partial vacuum within the evacuatable volume, and heating the composite laminate stack while applying suction to the evacuatable volume, thereby at least partially consolidating the laminate stack.

Abstract: A preform tool (30) for shaping uncured composite material, including a central section having a mold surface (40) corresponding to a surface of the desired component shape, and at least a first side section (34) detachably connected to the central section and having a support surface extending as a continuation of the mold surface, and a cover (36). The junction between the mold and support surface is located along an edge of the desired component shape. The cover is movable between an engaged position in proximity of the mold surface for retaining the composite material, and a disengaged position located further away from the mold surface than in the engaged position. Also, a method of shaping composite material includes conforming composite plies to the mold surface, disengaging each side section from the central section and trimming the excess composite material extending laterally from the mold surface.

Abstract: A method for forming a shaped composite structure. The method includes laying a composite laminate stack (12) onto a mold (18), where the composite laminate stack (12) comprises fabric laminate (14,16) and resin and wherein the mold (18) presents a predetermined shape, draping a vacuum film (22) comprising polyethylene onto the composite laminate stack (12), thereby establishing an evacuatable volume between the vacuum film (22) and the mold (18), applying suction to the evacuatable volume between the mold (18) and the vacuum film (22) to establish at least a partial vacuum within the evacuatable volume, thereby compressing the composite laminate stack (12) via pressure applied to the vacuum film (22) responsive to the at least partial vacuum within the evacuatable volume, and heating the composite laminate stack (12) while applying suction to the evacuatable volume, thereby at least partially consolidating the laminate stack (12).

Abstract: A method of preparing a composite element for forming a composite assembly having a cavity is disclosed. The method includes laying a barrier layer on a surface of the composite element which defines at least part of the cavity. A support assembly including a mandrel (38) and a film bag (40) extending on the surface of the mandrel is positioned with the film bag against the barrier layer. A sealed enclosure containing the composite element is formed through sealing engagement with the film bag. The pressure within the sealed enclosure is reduced, and the mandrel is separated from the film bag while maintaining the film bag positioned against the barrier layer. In one embodiment, the element is a stringer and is positioned against a skin. An assembly for forming a composite member is also provided.