Abstract: An aircraft has an airframe with a distributed thrust array attached thereto that includes a plurality of propulsion assemblies each of which is independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto and operable to tilt about a single axis. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector with a magnitude in the longitudinal direction. Actuation of each gimbal is operable to tilt the respective propulsion system relative to the airframe in the longitudinal direction to change the rotational plane of the respective rotor assembly relative to the airframe, thereby controlling the magnitude of the respective thrust vector in the longitudinal direction.

Abstract: A propulsion assembly for an aircraft includes a housing having a gimbal coupled thereto that is operable to tilt about first and second axes. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades. The rotor assembly is rotatable with the output drive of the electric motor in a rotational plane to generate thrust having a thrust vector with a direction. The first axis of the gimbal is orthogonal to the second axis of the gimbal. Actuation of the gimbal tilts the propulsion system relative to the housing to change the rotational plane of the rotor assembly relative to the housing, thereby controlling the direction of the thrust vector within a thrust vector cone.

Abstract: An aircraft has an airframe with a two-dimensional distributed thrust array attached thereto having a plurality of propulsion assemblies that are independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto that is operable to tilt about first and second axes responsive to first and second actuators. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector. Responsive to a thrust vector error of a first propulsion assembly, the flight control system commands at least a second propulsion assembly, that is symmetrically disposed relative to the first propulsion assembly, to counteract the thrust vector error, thereby providing redundant directional control for the aircraft.

Abstract: An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.

Abstract: One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.

Abstract: An aircraft having omnidirectional ground maneuver capabilities. The aircraft includes an airframe and a plurality of propulsion assemblies attached to the airframe. Each of the propulsion assemblies includes a nacelle having a mast axis, a rotor assembly having a tilting degree of freedom relative to the mast axis and a tail assembly rotatable about the mast axis. The tail assembly includes at least one wheel having a rotational axis. A flight control system is operable to independently control each of the propulsion assemblies including tilting each rotor assembly and rotating each tail assembly. For each propulsion assembly, the rotor assembly and the tail assembly have complementary configurations in which a thrust vector generated by the rotor assembly has a horizontal component that is generally perpendicular to the rotational axis of the wheel, thereby enabling omnidirectional ground maneuvers.

Abstract: An aerial imaging aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons coupled therebetween. The airframe has a longitudinal axis and a lateral axis in the VTOL orientation. A two-dimensional distributed thrust array is coupled to the airframe. The thrust array includes a plurality of propulsion assemblies each operable for variable speed and omnidirectional thrust vectoring. A payload is coupled to the airframe and includes an aerial imaging module. A flight control system is operable to independently control the speed and thrust vector of each of the propulsion assemblies such that in a level or inclined flight attitude, the flight control system is operable to maintain the orientation of the aerial imaging module toward a focal point of a ground object while translating the aircraft.

Abstract: In one embodiment, a method may comprise coupling a plurality of reinforcement fibers to a plurality of spherical components; inserting the plurality of spherical components into an enclosure; and heating the enclosure to cause the plurality of spherical components to expand, wherein the plurality of spherical components expands to form a geodesic structure, wherein the geodesic structure comprises a plurality of polyhedron components configured in a geodesic arrangement.

Abstract: An aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons coupled therebetween. The airframe has a longitudinal axis and a lateral axis in hover. A two-dimensional distributed thrust array is coupled to the airframe. The thrust array includes a plurality of propulsion assemblies each operable for variable speed and omnidirectional thrust vectoring. A flight control system is operable to independently control the speed and thrust vector of each of the propulsion assemblies such that in an inclined flight attitude with at least one of the longitudinal axis and the lateral axis extending out of a horizontal plane, the flight control system is operable to maintain hover stability responsive to controlling the speed and the thrust vector of the propulsion assemblies.

Abstract: Systems and methods for automated configuration of mission specific aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation.

Abstract: A rotor assembly for an aircraft is operable to generate a variable thrust vector. The rotor assembly includes a mast that is rotatable about a mast axis. A ball joint is positioned about and non rotatable with the mast. A tilt control assembly is positioned on and has a tilting degree of freedom relative to the ball joint. The tilt control assembly is non rotatable with the mast. A rotor hub is rotatably coupled to the tilt control assembly. The rotor hub is rotatable with the mast in a rotational plane and tiltable with the tilt control assembly. The rotor hub includes a plurality of grips each coupled to a rotor blade. Actuation of the tilt control assembly changes the rotational plane of the rotor hub relative to the mast axis, thereby generating the variable thrust vector.

Abstract: A mission configurable aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons extending therebetween. A two-dimensional distributed thrust array is attached to the airframe. The thrust array including a plurality of inboard propulsion assemblies coupled to first and second inboard nacelle stations of the first and second wings. The thrust array also includes a plurality of outboard propulsion assemblies coupled to first and second outboard nacelle stations of the first and second wings. A flight control system is operable to independently control each of the propulsion assemblies. A payload is coupled to the airframe. The inboard propulsion assemblies have a thrust type that is different from the thrust type of the outboard propulsion assemblies.

Abstract: An aircraft has an airframe including first and second wings with first and second pylons extending therebetween forming a closed wing. A distributed propulsion system attached to the airframe includes a plurality of propulsion assemblies that are independently controlled by a flight control system. A pod assembly is coupled to the airframe such that, in a VTOL flight mode, the first wing and at least two of the propulsion assemblies are forward of the pod assembly, the second wing and at least two of the propulsion assemblies are aft of the pod assembly and the pylons are lateral of the pod assembly. In addition, in a forward flight mode, the first wing and at least two of the propulsion assemblies are below the pod assembly, the second wing and at least two of the propulsion assemblies are above the pod assembly and the pylons are lateral of the pod assembly.

Abstract: An aircraft has an airframe including first and second wings with first and second pylons extending therebetween forming a closed wing. A distributed propulsion system attached to the airframe includes a plurality of propulsion assemblies that are independently controlled by a flight control system. A pod assembly is coupled to the airframe such that, in a VTOL flight mode, the first wing and at least two of the propulsion assemblies are forward of the pod assembly, the second wing and at least two of the propulsion assemblies are aft of the pod assembly and the pylons are lateral of the pod assembly. In addition, in a forward flight mode, the first wing and at least two of the propulsion assemblies are below the pod assembly, the second wing and at least two of the propulsion assemblies are above the pod assembly and the pylons are lateral of the pod assembly.

Abstract: A man portable aircraft system includes first and second wings with first and second pylons couplable between pylon stations thereof to form an airframe. Each of a plurality of propulsion assemblies is couplable to one of a plurality of nacelle stations of the wings to form a two-dimensional distributed thrust array. A flight control system is couplable to the airframe and is operable to independently control each of the propulsion assemblies. A payload is couplable between payload stations of the first and second pylons. A man portable container is operable to receive the wings, pylons, propulsion assemblies, flight control system and payload in a disassembled configuration. The connections between the wings, pylons, propulsion assemblies and payload are operable for rapid in-situ assembly. In an assembled configuration, the aircraft is operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation.

Abstract: An aircraft has an airframe with a two-dimensional distributed thrust array attached thereto having a plurality of propulsion assemblies that are independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto that is operable to tilt about first and second axes responsive to first and second actuators. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector. Responsive to a thrust vector error of a first propulsion assembly, the flight control system commands at least a second propulsion assembly, that is symmetrically disposed relative to the first propulsion assembly, to counteract the thrust vector error, thereby providing redundant directional control for the aircraft.

Abstract: An aircraft has an airframe with first and second wings having first and second pylons extending therebetween. A distributed propulsion system attached to the airframe includes a plurality of propulsion assemblies that are independently controlled by a flight control system. A pod assembly is coupled to the airframe. In a VTOL flight mode, the first wing is forward of the pod assembly and the second wing is aft of the pod assembly. In a forward flight mode, the first wing is below the pod assembly and the second wing is above the pod assembly. In both the VTOL flight mode and the forward flight mode, a first pair of symmetrically disposed propulsion assemblies generates thrust having a first direction while a second pair of symmetrically disposed propulsion assemblies generates thrust having a second direction that is different from the first direction.

Abstract: An aircraft is operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons extending therebetween forming a central region. A two-dimensional distributed thrust array and a flight control system are coupled to the airframe. A nose cone and an afterbody are each selectively coupled to the airframe. In a cargo delivery flight configuration, the nose cone and the afterbody are coupled to the airframe such that the nose cone and the afterbody each extend between the first and second wings and between first and second pylons to form a cargo enclosure with an aerodynamic outer shape. In a minimal drag flight configuration, the nose cone and the afterbody are not coupled to the airframe such that air passes through the central region during flight.

Abstract: A material dispensing system including a first frame and a first application head. The first application head supported by the first frame including a first bias ply assembly comprising a bias ply roll supported on a bias ply dispenser unit, the first bias ply assembly configured to pass bias ply material along a bias path; and a first non-bias ply assembly comprising a non-bias ply roll supported by a non-bias ply dispenser unit, the non-bias ply assembly configured to pass non-bias ply material along a non-bias path; wherein the bias path and the non-bias path are substantially parallel. Another aspect provides a material dispensing system including a first frame and a first application head supported thereby; and a second frame and a second application head supported thereby; wherein the first frame and the second frame move in an X direction during operation. Another aspect includes preparing a composite article.

Abstract: In one aspect, there is a rib assembly for an aircraft wing including a rib web having a top and a bottom, the rib web includes a first laminate, a second laminate, and a honeycomb panel having an array of large cells disposed between the first laminate and the second laminate, each cell having a width of at least 1 cm; and a plurality of skin flanges for fixedly attaching the rib web to a skin of the wing, each skin flange has a base member having a first portion and a second portion and a vertical member extending from the base member. The plurality of skin flanges can be attached to the top and the bottom of the rib web such that the second portion of the base member and the vertical member are attached to the rib web.