Abstract: A method for manufacturing a structure includes sensing activity in a workstation with at least one sensor. The method further includes transporting the structure to the workstation, engaging a telescoping platform with the structure, and releasing an access barrier after the engaging.

Abstract: A method for manufacturing a composite barrel structure includes fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The fabricating includes assembling a first layup of composite material and, concurrently, assembling at least one additional layup. The fabricating further includes heating the first layup with the at least one additional layup. A system for fabricating a plurality of panels that are assemblable into partial barrel sections includes a first workstation for fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The first workstation includes a first assembly station configured to concurrently assemble a first layup of composite material and at least one additional layup and a first heating station configured to heat the first layup concurrently with the at least one additional layup to yield the first plurality of composite panels.

Abstract: Methods and systems for assembling containerized aircraft as complete aircraft. The methods comprise removing aircraft components from shipping container(s), unloading the aircraft components from shipping fixture(s), removing tooling comprising aircraft component positioning structure(s) from the shipping container(s), loading aircraft component(s) onto aircraft component positioning structure(s), positioning the aircraft components in aircraft component installation positions, positioning the aircraft component(s) using the aircraft component positioning structure(s), and attaching the aircraft components to assemble the complete aircraft.

Abstract: Systems and methods are provided for demolding a composite part from a mandrel. The method includes mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has been hardened onto a mandrel, mechanically coupling a second arm of an extraction tool to a second arcuate portion of the composite part, and separating the composite part from the mandrel by iteratively performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm, and elastically straining the second arcuate portion of the composite part via the second arm.

Abstract: A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

Abstract: A system for post-cure processing a composite workpiece includes a tool. The tool includes a tool surface. The tool surface supports the composite workpiece located on the tool. The system also includes a drill template. The drill template defines a drilling location for drilling a hole through the composite workpiece while the composite workpiece is on the tool.

Abstract: A system includes a support beam elongated along a longitudinal axis. The support beam includes a first end portion longitudinally opposed from a second end portion, a first beam-side indexing feature proximate the first end portion, and a second beam-side indexing feature proximate the second end portion. The system further includes a first frame assembly having a first base portion, a first riser portion defining a first vertical axis, and a first carriage connected to the first riser portion and moveable relative to the first riser portion along the first vertical axis. The first carriage includes a first frame-side indexing feature configured to engage with the first beam-side indexing feature. The system further includes a second frame assembly having a second base portion, a second riser portion defining a second vertical axis, and a second carriage to the second riser portion and moveable relative to the second riser portion along the second vertical axis.

Abstract: A system for handling a composite workpiece includes a work cell and a plurality of workpiece holders to hold a composite workpiece in the work cell. Each one of the plurality of workpiece holders is selectively controlled to index the composite workpiece in the work cell and to conform the composite workpiece to an as-built shape of the composite workpiece.

Abstract: A system for damping machine-induced vibration in a workpiece includes a plurality of workpiece holders to hold the workpiece in a work cell. The system also includes a machine tool located in the work cell. The machine tool performs a machining operation on the workpiece while the workpiece is held by the plurality of workpiece holders. The system further includes a damping apparatus coupled to the workpiece. The damping apparatus controls machine-induced vibrations in the workpiece during the machining operation.

Abstract: A method for transporting a workpiece from an initial work cell to a subsequent work cell in a manufacturing environment having a plurality of work cells, the workpiece is supported by a support beam. The method includes monitoring the initial work cell for presence of a ready-to-move condition and monitoring the subsequent work cell for presence of a ready-to-receive condition. When both the ready-to-move condition and the ready-to-receive condition are present, the method includes interfacing the support beam with a gantry and, after the interfacing, moving the support beam with the gantry from the initial work cell to the subsequent work cell.

Abstract: A method for manufacturing a structure includes sensing activity in a workstation with at least one sensor. The method further includes transporting the structure to the workstation, engaging a telescoping platform with the structure, and releasing an access barrier after the engaging.

Abstract: A method for manufacturing a composite barrel structure includes fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The fabricating includes assembling a first layup of composite material and, concurrently, assembling at least one additional layup. The fabricating further includes heating the first layup with the at least one additional layup. A system for fabricating a plurality of panels that are assemblable into partial barrel sections includes a first workstation for fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The first workstation includes a first assembly station configured to concurrently assemble a first layup of composite material and at least one additional layup and a first heating station configured to heat the first layup concurrently with the at least one additional layup to yield the first plurality of composite panels.

Abstract: Methods and systems for assembling containerized aircraft as complete aircraft. The methods comprise removing aircraft components from shipping container(s), unloading the aircraft components from shipping fixture(s), removing tooling comprising aircraft component positioning structure(s) from the shipping container(s), loading aircraft component(s) onto aircraft component positioning structure(s), positioning the aircraft components in aircraft component installation positions, positioning the aircraft component(s) using the aircraft component positioning structure(s), and attaching the aircraft components to assemble the complete aircraft.

Abstract: A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

Abstract: Methods and systems for assembling containerized aircraft as complete aircraft. The methods comprise removing aircraft components from shipping container(s), unloading the aircraft components from shipping fixture(s), removing tooling comprising aircraft component positioning structure(s) from the shipping container(s), loading aircraft component(s) onto aircraft component positioning structure(s), positioning the aircraft components in aircraft component installation positions, positioning the aircraft component(s) using the aircraft component positioning structure(s), and attaching the aircraft components to assemble the complete aircraft.

Abstract: Systems and methods are provided for demolding a composite part from a mandrel. The method includes mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has been hardened onto a mandrel, mechanically coupling a second arm of an extraction tool to a second arcuate portion of the composite part, and separating the composite part from the mandrel by iteratively performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm, and elastically straining the second arcuate portion of the composite part via the second arm.

Abstract: A method of manufacturing a wing assembly for joining to a fuselage of an aircraft includes the steps of loading a center wing section into a wing join station, loading a right wing section into the wing join station proximate to the center wing section, loading a left wing section into the wing join station proximate to the center wing section, joining the right and left wing sections to the center wing section to form a complete wing assembly, moving the complete wing assembly to a processing station, performing drilling operations on the complete wing assembly at the processing station, installing fasteners in the complete wing assembly at the processing station, and moving the complete wing assembly to a wing-body join station to join the complete wing assembly to the fuselage.

Abstract: Methods and systems for assembling containerized aircraft as complete aircraft. The methods comprise removing aircraft components from shipping container(s), unloading the aircraft components from shipping fixture(s), removing tooling comprising aircraft component positioning structure(s) from the shipping container(s), loading aircraft component(s) onto aircraft component positioning structure(s), positioning the aircraft components in aircraft component installation positions, positioning the aircraft component(s) using the aircraft component positioning structure(s), and attaching the aircraft components to assemble the complete aircraft.

Abstract: A method and system for alleviating a load is provided. A support system is positioned at a nominal location with respect to an object. The support system comprises jacks and supports. Each of the supports is associated with one of the jacks. The object is positioned on the support system. The support system with the object is moved across a path. The height of each of the jacks is adjusted as the support system moves along the path to maintain a desired minimum load on each jack. Maintaining the desired minimum load prevents damage to the object.

Abstract: A fuselage cradle support assembly, which can be used as part of a jacking system during aircraft manufacture, is described. The fuselage cradle support assembly can include an array of fuselage cradles. The fuselage cradle support assembly can be configured to limit motion of each fuselage cradle in a cradle array to only vertical and horizontal movements. The vertical movements can be generated using actuators, such as hydraulic actuators, which are communicatively coupled to one another to distribute loads within the cradle array.