Abstract: An apparatus and method configured for manufacturing an aircraft part from formable material. The apparatus may include one or more rigid forming components onto which the formable material is placed and between which non-flange portions of the formable material may be compressed, and at least one inflatable component that, when expanded by inflation, presses flange portions of the formable material against at least one of the rigid forming components. The inflation component(s) may be arranged in any configuration for forming the formable material into C-shaped channels, single L-shaped channels, or opposing Z-shaped channels. Once pressed between the rigid forming components and/or the inflated inflatable components, the formable material may be heated for forming according to the particular formable material used.

Abstract: A through-transmission ultrasonic (TTU) inspection system for ultrasonic inspection of a part and for determining alignment calibration data for increased alignment accuracy. The TTU inspection system may include first and second end effectors located on opposite sides of the part, each having at least one transducer for transmitting or receiving ultrasonic or sound waves through the part. The TTU inspection system may also include actuators and a system controller. The system controller may command the actuators to actuate the first end effector according to one or more scanning patterns, while the transducers send and/or receive signals to or from each other through the part. The system controller may use signal strength measurements received along these scanning patterns to determine alignment calibration data for applying to the first end effector and/or its associated actuators.

Abstract: An apparatus and method configured for manufacturing an aircraft part from formable material. The apparatus may include one or more rigid forming components onto which the formable material is placed and between which non-flange portions of the formable material may be compressed, and at least one inflatable component that, when expanded by inflation, presses flange portions of the formable material against at least one of the rigid forming components. The inflation component(s) may be arranged in any configuration for forming the formable material into C-shaped channels, single L-shaped channels, or opposing Z-shaped channels. Once pressed between the rigid forming components and/or the inflated inflatable components, the formable material may be heated for forming according to the particular formable material used.

Abstract: A through-transmission ultrasonic (TTU) inspection system for ultrasonic inspection of a part and for determining alignment calibration data for increased alignment accuracy. The TTU inspection system may include first and second end effectors located on opposite sides of the part, each having at least one transducer for transmitting or receiving ultrasonic or sound waves through the part. The TTU inspection system may also include actuators and a system controller. The system controller may command the actuators to actuate the first end effector according to one or more scanning patterns, while the transducers send and/or receive signals to or from each other through the part. The system controller may use signal strength measurements received along these scanning patterns to determine alignment calibration data for applying to the first end effector and/or its associated actuators.

Abstract: An apparatus for laminating a fabric material to a part broadly comprises a vacuum table, a cutting element, a plurality of pinch rollers, and a plurality of compaction rollers. The vacuum table receives the fabric material from a supply spool and retains the material while the cutting element cuts scrap material from the sides of the fabric material. The pinch rollers receive the fabric material after the scrap material has been cut and are configured to stretch the fabric material from a center line outward toward the edges of the material. The compaction rollers receive the fabric material from the pinch rollers and are configured to press the fabric material against a surface of the part.

Abstract: An apparatus for laminating a fabric material to a part broadly comprises a vacuum table, a cutting element, a plurality of pinch rollers, and a plurality of compaction rollers. The vacuum table receives the fabric material from a supply spool and retains the material while the cutting element cuts scrap material from the sides of the fabric material. The pinch rollers receive the fabric material after the scrap material has been cut and are configured to stretch the fabric material from a center line outward toward the edges of the material. The compaction rollers receive the fabric material from the pinch rollers and are configured to press the fabric material against a surface of the part.