Abstract: An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is also provided that permits differential expansion of different portions of the tool.

Abstract: A beaded composite panel is fabricated using composite plies. An opening is formed in each of plies, and each ply is laid up on a bead feature and drawn down over the bead feature in the area of the opening so as to widen the opening into a gap allowing the ply to conform to the contour of the bead feature. Patches are fabricated and placed on the plies overlying over the openings. The laid-up plies are compacted and cured.

Abstract: A system for supporting a bond jig comprises a plurality of planar panels including at least one mounting hole for fasteners in each panel, wherein a first panel is arranged in a non-orthogonal position to a second panel. The system further comprises a coupling element for coupling panels, comprising a first and second planar portion, a hinge element connecting the first and second planar portion, wherein the first planar portion and the second planar portion rotate around the hinge element to form an angle, and at least one mounting hole for fasteners in the first and second planar portion. The system further comprises at least one fastener for fastening the first planar portion to the first panel via a mounting hole in the first planar portion and a mounting hole in the first panel and at least one fastener for fastening the second planar portion to the second panel via the mounting hole in the second planar portion and the mounting hole in the second panel.

Abstract: A tool for trimming the ends of stiffeners on aircraft composite skin panels accurately, rapidly and without damaging the underlying skins includes an expandable guide frame adapted to straddle and clamp to the stiffener at a selected longitudinal position thereon. The frame includes a pair of planar guide faces disposed on opposite sides of the stiffener and lying in a common plane transverse thereto. The rotatably supported opposite ends of a rotating abrasive drum are slid along respective ones of the guide faces such that the drum grinds away the stiffener in a plane parallel to the plane of the guide faces and thereby forms a trimmed end on the stiffener. The frame includes mechanisms for adjusting the angular inclination of the plane of the guide faces relative to the plane of the composite skin, and for preventing the grinding mechanism from cutting into the composite skin.

Abstract: In one embodiment, an apparatus for curing a composite assembly may include a base tool, a growth control apparatus, and at least one engagement filling. The base tool may have a different thermal expansion growth rate than a composite assembly to be cured using the apparatus. The growth control apparatus may have a different thermal expansion growth rate than the base tool. The engagement fitting may be movably disposed relative to the base tool and connected to the growth control apparatus. The engagement filling may hold a composite assembly being cured against the engagement filling. The growth control apparatus may grow a pre-determined amount during curing of a composite assembly to produce a cured composite assembly having a pre-determined design dimension.

Abstract: A pressure debulking system includes a debulking chamber having a debulking chamber interior, a pressure bladder having a bladder interior provided in the debulking chamber interior, a vacuum port disposed in fluid communication with the debulking chamber interior and a pressure port disposed in fluid communication with the debulking chamber interior. A pressure debulking method is also disclosed.

Abstract: A tool used to direct the pressure applied to features of a plastic laminate part layup during co-curing or co-bonding is manufactured using direct digital manufacturing techniques. A CAD drawing representing the tool is generated and converted into digital data file suitable for controlling the operation of a rapid prototyping machine. The tool is formed in the rapid prototyping machine by additive layering of material until the features and dimensions of the layered material correspond to the CAD drawing. The resulting tool exhibits geometries and dimensions virtually identical to the theoretical dimensions of the CAD model of the tool.

Abstract: An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is also provided that permits differential expansion of different portions of the tool.

Abstract: A tool for trimming the ends of stiffeners on aircraft composite skin panels accurately, rapidly and without damaging the underlying skins includes an expandable guide frame adapted to straddle and clamp to the stiffener at a selected longitudinal position thereon. The frame includes a pair of planar guide faces disposed on opposite sides of the stiffener and lying in a common plane transverse thereto. The rotatably supported opposite ends of a rotating abrasive drum are slid along respective ones of the guide faces such that the drum grinds away the stiffener in a plane parallel to the plane of the guide faces and thereby forms a trimmed end on the stiffener. The frame includes mechanisms for adjusting the angular inclination of the plane of the guide faces relative to the plane of the composite skin, and for preventing the grinding mechanism from cutting into the composite skin.

Abstract: A tool used to direct the pressure applied to features of a plastic laminate part layup during co-curing or co-bonding is manufactured using direct digital manufacturing techniques. A CAD drawing representing the tool is generated and converted into digital data file suitable for controlling the operation of a rapid prototyping machine. The tool is formed in the rapid prototyping machine by additive layering of material until the features and dimensions of the layered material correspond to the CAD drawing. The resulting tool exhibits geometries and dimensions virtually identical to the theoretical dimensions of the CAD model of the tool.

Abstract: A system for supporting a bond jig comprises a plurality of planar panels including at least one mounting hole for fasteners in each panel, wherein a first panel is arranged in a non-orthogonal position to a second panel. The system further comprises a coupling element for coupling panels, comprising a first and second planar portion, a hinge element connecting the first and second planar portion, wherein the first planar portion and the second planar portion rotate around the hinge element to form an angle, and at least one mounting hole for fasteners in the first and second planar portion. The system further comprises at least one fastener for fastening the first planar portion to the first panel via a mounting hole in the first planar portion and a mounting hole in the first panel and at least one fastener for fastening the second planar portion to the second panel via the mounting hole in the second planar portion and the mounting hole in the second panel.

Abstract: The invention provides an apparatus and method for testing the tensile load bearing properties of a sample of uncured prepreg composite material. The apparatus includes a housing comprising an internal cavity for receiving a sample to be tested. It also has a bladder and a block located at least partially within the housing such that inflating the bladder applies pressure to the prepreg sample by urging the block into the sample cavity, against the sample. In addition, the apparatus includes a heater for applying controlled heat to the sample and thermocouples for measuring sample temperature. Ends of the sample prepreg are accessible to jaws of a tensile load testing machine, and load is applied when the desired temperature and pressure are obtained.

Abstract: The invention provides an apparatus and method for testing the tensile load bearing properties of a sample of uncured prepreg composite material. The apparatus includes a housing comprising an internal cavity for receiving a sample to be tested. It also has a bladder and a block located at least partially within the housing such that inflating the bladder applies pressure to the prepreg sample by urging the block into the sample cavity, against the sample. In addition, the apparatus includes a heater for applying controlled heat to the sample and thermocouples for measuring sample temperature. Ends of the sample prepreg are accessible to jaws of a tensile load testing machine, and load is applied when the desired temperature and pressure are obtained.