Abstract: Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Abstract: A rotor assembly for a fixed-wing VTOL aircraft. The rotor assembly is configured to provide vertical flight for the fixed-wing VTOL aircraft. In one embodiment, the rotor assembly includes a hub assembly, a first rotor blade affixed to the hub assembly, and a second rotor blade affixed to the hub assembly. The hub assembly orients the second rotor blade in relation to the first rotor blade about an axis of rotation of the hub assembly with the first rotor blade and the second rotor blade vertically stacked when the hub assembly is stopped for wing-borne flight.

Abstract: A method for computer analysis of a quality of an as-programmed surface of a composite laminate. A first data set representing an as-programmed top surface is generated based on as-programmed ply definitions and a tool surface definition. Thereafter, a second data set representing coordinates of points of a first mesh on the as-programmed top surface is generated, which points form a first mesh. Then a third data set representing coordinates of points of a second mesh on a defined tool surface is generated. A respective angle of each mesh element of the first mesh relative to a corresponding mesh element of the second mesh is then calculated. Each angle is compared to a threshold of acceptable angle. In response to an acceptable number of angles exceeding a threshold of acceptable angle, a tow placement machine may be programmed to fabricate a composite structure using the as-programmed ply definitions.

Abstract: Systems and methods are provided for splicing airframe components. One embodiment is a method for assembling an airframe of an aircraft. The method includes forming a first skin of a first circumferential section of fuselage, the first skin including a distal portion comprising a lip and a shoulder, aligning a second skin of a second circumferential section of fuselage with the shoulder such that the lip overlaps the second skin, and affixing the first skin and the second skin together via a circumferential splice.

Abstract: System and method for loading cargo onto an unmanned aerial vehicle (UAV). One embodiment is a cargo pod for an unmanned aerial vehicle (UAV). The cargo pod includes a hollow body that forms a section of a fuselage of the UAV, and further includes a latching mechanism that releasably secures the hollow body with the fuselage of the UAV.

Abstract: A rotor assembly for a fixed-wing VTOL aircraft. The rotor assembly is configured to provide vertical flight for the fixed-wing VTOL aircraft. In one embodiment, the rotor assembly includes a hub assembly, a first rotor blade affixed to the hub assembly, and a second rotor blade affixed to the hub assembly. The hub assembly orients the second rotor blade in relation to the first rotor blade about an axis of rotation of the hub assembly with the first rotor blade and the second rotor blade vertically stacked when the hub assembly is stopped for wing-borne flight.

Abstract: A rotor assembly for a fixed-wing VTOL aircraft. The rotor assembly is configured to provide vertical flight for the fixed-wing VTOL aircraft. In one embodiment, the rotor assembly includes a hub assembly, a first rotor blade affixed to the hub assembly, and a second rotor blade affixed to the hub assembly. The hub assembly orients the second rotor blade in relation to the first rotor blade about an axis of rotation of the hub assembly with the first rotor blade and the second rotor blade vertically stacked when the hub assembly is stopped for wing-borne flight.

Abstract: A composite structural member and an arrangement of such composite structural members are constructed to provide a multi-functional under-floor airframe that reacts flight, handling and internal cargo loads, and is capable of absorbing energy when subjected to vertically applied compression loads, such as loads that may be applied in hard landing or crash situations. The composite structural member and arrangement of such composite structural members adds no parasitic weight to the aircraft, i.e., there is no need for additional energy-absorbing systems, structures or mechanism; and is lighter weight as compared to metal. The composite structural member and related parts of the arrangement of such composite structural members are designed to progressively collapse throughout the stroke (or displacement) that occurs when a dynamic compressive load is applied to the structural member and to work together with crashworthy seats to mitigate injuries to occupants.

Abstract: A vibration damper including a frame having at least a first cavity, a frame first end and a frame second end spaced from the frame first end; a shaft slidably coupled to and extending into the frame where the shaft extends through the first cavity; a first vibration isolator disposed within the first cavity where the shaft extends through the first vibration isolator so as to capture the first vibration isolator within the first cavity where the first vibration isolator interfaces with the frame second end; and a second vibration isolator disposed on the shaft, where the shaft extends through the second vibration isolator so as to capture the second vibration isolator on the shaft where the second vibration isolator interfaces with the frame second end opposite the first vibration isolator, where the first vibration isolator and the second vibration isolator act only in compression.

Abstract: System and method for loading cargo onto an unmanned aerial vehicle (UAV). One embodiment is a cargo pod for an unmanned aerial vehicle (UAV). The cargo pod includes a hollow body that forms a section of a fuselage of the UAV, and further includes a latching mechanism that releasably secures the hollow body with the fuselage of the UAV.

Abstract: A rotor assembly for a fixed-wing VTOL aircraft. The rotor assembly is configured to provide vertical flight for the fixed-wing VTOL aircraft. In one embodiment, the rotor assembly includes a hub assembly, a first rotor blade affixed to the hub assembly, and a second rotor blade affixed to the hub assembly. The hub assembly orients the second rotor blade in relation to the first rotor blade about an axis of rotation of the hub assembly with the first rotor blade and the second rotor blade vertically stacked when the hub assembly is stopped for wing-borne flight.

Abstract: A composite structural member and an arrangement of such composite structural members are constructed to provide a multi-functional under-floor airframe that reacts flight, handling and internal cargo loads, and is capable of absorbing energy when subjected to vertically applied compression loads, such as loads that may be applied in hard landing or crash situations. The composite structural member and arrangement of such composite structural members adds no parasitic weight to the aircraft, i.e., there is no need for additional energy-absorbing systems, structures or mechanism; and is lighter weight as compared to metal. The composite structural member and related parts of the arrangement of such composite structural members are designed to progressively collapse throughout the stroke (or displacement) that occurs when a dynamic compressive load is applied to the structural member and to work together with crashworthy seats to mitigate injuries to occupants.

Abstract: A tool for laying up composite material to form a workpiece having a target contour is disclosed. The tool includes a support structure including an elongated member having a longitudinal axis, and support plates connected to the elongated member and spaced apart from each other along the longitudinal axis. The elongated member includes a metallic material. The tool also includes a non-metallic backing structure connected to the support plates, the non-metallic backing structure comprising a working surface that includes a backing contour complementary to the target contour.

Abstract: A vibration damper including a frame having at least a first cavity, a frame first end and a frame second end spaced from the frame first end; a shaft slidably coupled to and extending into the frame where the shaft extends through the first cavity; a first vibration isolator disposed within the first cavity where the shaft extends through the first vibration isolator so as to capture the first vibration isolator within the first cavity where the first vibration isolator interfaces with the frame second end; and a second vibration isolator disposed on the shaft, where the shaft extends through the second vibration isolator so as to capture the second vibration isolator on the shaft where the second vibration isolator interfaces with the frame second end opposite the first vibration isolator, where the first vibration isolator and the second vibration isolator act only in compression.

Abstract: Technologies for fused filament fabrication using multi-directional layering are disclosed herein. According to aspects of the disclosure, a component may be strengthened using a multi-directional layering manufacturing technique. In some implementations, one or more portions of the component are manufactured in different orientations. In still further implementations, one layer of a component is laid down in a first orientation and a second layer of the component is laid down in a second orientation.

Abstract: One example of the present disclosure relates to a tool for laying up composite material to form a workpiece having a target contour. The tool includes a support structure including an elongated member having a longitudinal axis, and support plates connected to the elongated member and spaced apart from each other along the longitudinal axis. The elongated member includes a metallic material. The tool also includes a non-metallic backing structure connected to the support plates, the non-metallic backing structure comprising a working surface that includes a backing contour complementary to the target contour.

Abstract: One example of the present disclosure relates to a tool for laying up composite material to form a workpiece having a target contour. The tool includes a support structure including an elongated member having a longitudinal axis, and support plates connected to the elongated member and spaced apart from each other along the longitudinal axis. The elongated member includes a metallic material. The tool also includes a non-metallic backing structure connected to the support plates, the non-metallic backing structure comprising a working surface that includes a backing contour complementary to the target contour.

Abstract: An energy absorbing fitting is constructed to absorb tension, shear and compression loads at a joint between two composite material beams of a composite material frame. The fitting is constructed with a band of composite material having an inverted U-shape, a panel of composite material having a U-shaped cross-section configuration that is assembled into the inverted U-shaped configuration of the band, and a sheet of composite material having an inverted L-shape configuration that is secured to the band and to the panel. The fitting is positioned at the intersection of the beams and is secured to the joint between the beams, thereby reinforcing the joint against tension, shear and compression loads.

Abstract: An apparatus and method for a composite structural aircraft transmission support link having an integral energy-absorbing feature is disclosed. The link is a two-force member that can carry structural loads up an ultimate load. When loaded beyond ultimate load the design allows sections of the link to fail in a controlled and progressive manner, so that energy is absorbed over a defined stroking distance.

Abstract: An energy absorbing fitting is constructed to absorb tension, shear and compression loads at a joint between two composite material beams of a composite material frame. The fitting is constructed with a band of composite material having an inverted U-shape, a panel of composite material having a U-shaped cross-section configuration that is assembled into the inverted U-shaped configuration of the band, and a sheet of composite material having an inverted L-shape configuration that is secured to the band and to the panel. The fitting is positioned at the intersection of the beams and is secured to the joint between the beams, thereby reinforcing the joint against tension, shear and compression loads.