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: 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 aircraft has a vertical takeoff and landing fight mode and a forward flight mode. The aircraft includes an airframe with first and second M-wings each having a pair of leading apexes with swept forward and swept back portions extending therefrom at a swept angle. A propulsion system includes a plurality of propulsion assemblies each attached to the airframe proximate one of the leading apexes. Each of the propulsion assemblies includes a rotor assembly having a tilting degree of freedom. A flight control system is operable to control the propulsion assemblies including tilting the rotor assemblies to generate variable thrust vectors that have a maximum angle that is generally congruent with the swept angles of the M-wings.

Abstract: A rotor assembly for an aircraft operable to generate a variable thrust output at a constant rotational speed. The rotor assembly includes a mast rotatable at the constant speed about a mast axis. A rotor hub is coupled to and rotatable with the mast. The rotor hub includes a plurality of spindle grips extending generally radially outwardly. Each of the spindle grips is coupled to one of a plurality of rotor blades and is operable to rotate therewith about a pitch change axis. A collective pitch control mechanism is coupled to and rotatable with the rotor hub. The collective pitch control mechanism is operably associated with each spindle grip such that actuation of the collective pitch control mechanism rotates each spindle grip about the respective pitch change axis to collectively control the pitch of the rotor blades, thereby generating the variable thrust output.

Abstract: An aircraft operable to transition between a forward flight mode and a vertical takeoff and landing flight mode. The aircraft includes an airframe having first and second wings. A plurality of propulsion assemblies is attached to the airframe with each of the propulsion assemblies including a nacelle and a tail assembly having at least one active aerosurface. A flight control system is operable to independently control each of the propulsion assemblies. For each of the propulsion assemblies, the tail assembly is rotatable relative to the nacelle such that the active aerosurface has a first orientation generally parallel to the wings and a second orientation generally perpendicular to the wings.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.

Abstract: An aircraft has multiple independent yaw authority mechanisms. The aircraft includes an airframe having first and second wings with at least first and second pylons extending therebetween and with a plurality of tail members extending therefrom each having an active control surface. A two-dimensional distributed thrust array is coupled to the airframe that includes a plurality of propulsion assemblies each having a rotor assembly and each operable for thrust vectoring. A flight control system is operable to independently control each of the propulsion assemblies. A first yaw authority mechanism includes differential speed control of rotor assemblies rotating clockwise compared to rotor assemblies rotating counterclockwise. A second yaw authority mechanism includes differential longitudinal control surface maneuvers of control surfaces of two symmetrically disposed tail members. A third yaw authority mechanism includes differential thrust vectoring of propulsion assemblies.

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: 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: In some embodiments, a pod assembly transportation system includes a transportation services provider computing system and a plurality of flying frame flight control systems, wherein the system is configured to receive, at the transportation services provider computing system, a request for transportation of a pod assembly; upload a flight plan to a flight control system of a flying frame including an airframe and a distributed propulsion system coupled to airframe; dispatch the flying frame by air to the current location of the pod assembly; couple the pod assembly to the flying frame; transport the pod assembly by air from the current location of the pod assembly to the destination of the pod assembly including transitioning the flying frame between a vertical takeoff and landing mode and a forward flight mode; and decouple the pod assembly from the flying frame at the destination of the pod assembly.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

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: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: In some embodiments, a passenger pod assembly transportation system includes a transportation services provider computing system and a plurality of flying frame flight control systems, wherein the system is configured to receive, at the transportation services provider computing system, a request for transportation of a passenger pod assembly having a current location and a destination; upload a flight plan to a flight control system of a flying frame including an airframe and a propulsion system; dispatch the flying frame to the current location of the passenger pod assembly; couple the flying frame to the passenger pod assembly at the current location of the passenger pod assembly; transport the passenger pod assembly by air from the current location of the passenger pod assembly to the destination of the passenger pod assembly; and decouple the passenger pod assembly from the flying frame at the destination of the passenger pod assembly.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

Abstract: A tiltrotor aircraft includes a fuselage, a wing member extending from the fuselage, an engine disposed relative to the wing member, a rotor hub assembly mechanically coupled to the engine and a plurality of proprotor blade assemblies rotatably mounted to the rotor hub assembly and operable for beamwise folding relative thereto. The proprotor blade assemblies each including a spar and a sheath extending spanwise along a leading edge of the spar. The spar has a root section, a main section and a tip section. The spar has a generally oval cross section at radial stations along the main section of the spar with the root section of the spar forming an integral tang assembly operable for coupling the spar to the rotor hub assembly.

Abstract: In some embodiments, an aircraft includes a flying frame having an airframe, a propulsion system attached to the airframe and a flight control system operably associated with the propulsion system wherein, the flying frame has a vertical takeoff and landing mode and a forward flight mode. A pod assembly is selectively attachable to the flying frame such that the flying frame is rotatable about the pod assembly wherein, the pod assembly remains in a generally horizontal attitude during vertical takeoff and landing, forward flight and transitions therebetween.

Abstract: In some embodiments, an aircraft includes a flying frame having an airframe, a distributed propulsion system attached to the airframe, a flight control system operably associated with the distributed propulsion system and a pod assembly selectively attachable to the flying frame. The distributed propulsion system includes a plurality of propulsion assemblies that are independently controlled by the flight control system, thereby enabling the flying frame to have a vertical takeoff and landing mode and a forward flight mode.

Abstract: In some embodiment, an aircraft includes a flying frame having an airframe, a distributed propulsion system attached to the airframe, the distributed propulsion system including a plurality of propulsion assemblies and a flight control system operably associated with the distributed propulsion system. The flying frame has a vertical takeoff and landing mode and a forward flight mode. The flight control system is operable to independently control the propulsion assemblies. The flight control system is also operable to detect faults in individual propulsion assemblies and to perform corrective action responsive to detected faults at a distributed propulsion system level.

Abstract: In some embodiments, a transportation method includes coupling a flying frame to a passenger pod assembly; lifting the passenger pod assembly into the air in a vertical takeoff and landing mode with the passenger pod assembly in a generally horizontal attitude; transitioning from the vertical takeoff and landing mode to a forward flight mode by rotating the flying frame relative to the passenger pod assembly, which remains in the generally horizontal attitude; transporting the passenger pod assembly toward a second location in the forward flight mode; transitioning the flying frame from the forward flight mode to the vertical takeoff and landing mode by rotating the flying frame relative to the passenger pod assembly, which remains in the generally horizontal attitude; landing the flying frame at the second location in the vertical takeoff and landing mode; and releasing the passenger pod assembly.