Abstract: Composite joints and methods of forming composite joints are presented. A composite joint comprising: a first composite component formed of one of a thermoset material or a first thermoplastic material; a second composite component formed of a thermoset material or a third thermoplastic material; a thermoplastic joining film formed of a second thermoplastic material between the first composite component and the second composite component, the second thermoplastic material different from the thermoset material, first thermoplastic material, and third thermoplastic material; and a carbon conductive layer in the thermoplastic joining film.

Abstract: A manufacturing system includes a stator base, a plurality of movers, one or more end effectors, and a controller. The stator base has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. The movers each contain multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field. The end effectors are coupled to the movers, and each end effector perform one or more functions in relation to a material sheet. The controller activates the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with and operate on the material sheet.

Abstract: A system to aid in design for manufacturing an object includes a processor and a memory configured to store instructions. The processor is configured to receive first data representing a design of the object to be manufactured and second data representing a machine-learning model. The processor is configured to execute the instructions to generate third data using the first data and the second data. The third data indicates at least one of a modification to the design of the object or process conditions for production of the object. The processor is configured to send the design of the object, the process conditions, or both, to a manufacturing tool to enable production of the object. The machine-learning model is representative of production data and based at least partially on one or more of: object features, process parameters, environmental factors, and quality data.

Abstract: Thermoplastic assemblies, methods of defining thermoplastic assemblies, aircraft that include the thermoplastic assemblies, and aircraft that are formed utilizing the methods are disclosed herein. The methods include heating a joining structure and pressing a thermoplastic layer against a base of the joining structure. The pressing includes transferring thermal energy from the joining structure to the thermoplastic layer and penetrating the thermoplastic layer with a plurality of reinforcing projections of the joining structure. The pressing also includes adhering the thermoplastic layer to a surface of the base and to a surface of the plurality of reinforcing projections. The thermoplastic assemblies include the thermoplastic layer and the joining structure.

Abstract: A system to aid in design for manufacturing an object includes a processor and a memory configured to store instructions. The processor is configured to receive first data representing a design of the object to be manufactured and second data representing a machine-learning model. The processor is configured to execute the instructions to generate third data using the first data and the second data. The third data indicates at least one of a modification to the design of the object or process conditions for production of the object. The processor is configured to send the design of the object, the process conditions, or both, to a manufacturing tool to enable production of the object. The machine-learning model is representative of production data and based at least partially on one or more of: object features, process parameters, environmental factors, and quality data.

Abstract: Thermoplastic assemblies, methods of defining thermoplastic assemblies, aircraft that include the thermoplastic assemblies, and aircraft that are formed utilizing the methods are disclosed herein. The methods include heating a joining structure and pressing a thermoplastic layer against a base of the joining structure. The pressing includes transferring thermal energy from the joining structure to the thermoplastic layer and penetrating the thermoplastic layer with a plurality of reinforcing projections of the joining structure. The pressing also includes adhering the thermoplastic layer to a surface of the base and to a surface of the plurality of reinforcing projections. The thermoplastic assemblies include the thermoplastic layer and the joining structure.

Abstract: A method and apparatus for laying composite tape. The method may comprise driving a plurality of robots, each having a respective movement system across a movement surface, in which the movement surface faces a workpiece, and laying composite tape from the plurality of robots in a coordinated manner on the workpiece.

Abstract: A method of repairing a structure is provided. The method includes inspecting the structure with a robotic device to identify a structural defect in the structure, generating a tool path for repairing the structural defect, and transmitting the tool path to the robotic device from a location remote from the robotic device.

Abstract: A base assembly for coupling an end effector to a structure includes a first side and an opposite second side. The first side configured to couple to the end effector. The base assembly also includes at least one cavity disposed on the second side, and at least one pneumatic generator coupled in flow communication with the at least one cavity. The at least one pneumatic generator is operable in a suction mode and a blower mode. The second side having the at least one cavity is securely coupleable to a surface of the structure via a vacuum force induced by the at least one pneumatic generator in the suction mode, and the second side having the at least one cavity is movable substantially frictionlessly across the surface via an air cushion induced by the at least one pneumatic generator in the blower mode.

Abstract: A method and apparatus for a robot self-locating on a movement surface. The method may comprise moving a first robot across the movement surface and relative to a workpiece, in which the movement surface faces the workpiece. The method may also form sensor data using a first number of sensors on the first robot as the first robot moves across the movement surface, in which the sensor data represents identifying characteristics of a portion of the movement surface. The method may also determine a location of the first robot on the movement surface using the sensor data. The method may further determine a location of a functional component of the first robot relative to the workpiece using the location of the first robot on the movement surface.

Abstract: A method and apparatus for performing manufacturing functions on a workpiece. The apparatus may comprise a base, a plurality of autonomous functional components, and a plurality of autonomous movement systems. Each functional component of the plurality of autonomous functional components may be configured to perform a respective function. The plurality of autonomous movement systems may be associated with the base. Each of the plurality of autonomous movement systems may be connected to a respective functional component of the plurality of autonomous functional components.

Abstract: A method and apparatus for customizing tool paths. A reference tool path is identified for a tool based on an expected shape for a surface of an object. Offset data is generated for a plurality of sample points identified for use in evaluating the surface of the object. The offset data identifies a difference between the expected shape for the surface of the object and an actual shape of the surface of the object. The reference tool path is modified using the offset data to form a modified tool path for the tool.

Abstract: A method and apparatus for laying composite tape. The method may comprise driving a plurality of robots, each having a respective movement system across a movement surface, in which the movement surface faces a workpiece, and laying composite tape from the plurality of robots in a coordinated manner on the workpiece.

Abstract: A method and apparatus for a robot self-locating on a movement surface. The method may comprise moving a first robot across the movement surface and relative to a workpiece, in which the movement surface faces the workpiece. The method may also form sensor data using a first number of sensors on the first robot as the first robot moves across the movement surface, in which the sensor data represents identifying characteristics of a portion of the movement surface. The method may also determine a location of the first robot on the movement surface using the sensor data. The method may further determine a location of a functional component of the first robot relative to the workpiece using the location of the first robot on the movement surface.

Abstract: A method and apparatus for performing manufacturing functions on a workpiece. The apparatus may comprise a base, a plurality of autonomous functional components, and a plurality of autonomous movement systems. Each functional component of the plurality of autonomous functional components may be configured to perform a respective function. The plurality of autonomous movement systems may be associated with the base. Each of the plurality of autonomous movement systems may be connected to a respective functional component of the plurality of autonomous functional components.

Abstract: A manufacturing control system comprises a vision system for viewing operations within a manufacturing area and for producing vision data representing the viewed operations. A systems control analyzes the vision data, and controls at least two control functions related to the manufacturing operations based on the analyzed vision data.

Abstract: A base assembly for coupling an end effector to a structure includes a first side and an opposite second side. The first side configured to couple to the end effector. The base assembly also includes at least one cavity disposed on the second side, and at least one pneumatic generator coupled in flow communication with the at least one cavity. The at least one pneumatic generator is operable in a suction mode and a blower mode. The second side having the at least one cavity is securely coupleable to a surface of the structure via a vacuum force induced by the at least one pneumatic generator in the suction mode, and the second side having the at least one cavity is movable substantially frictionlessly across the surface via an air cushion induced by the at least one pneumatic generator in the blower mode.

Abstract: A method of repairing a structure is provided. The method includes inspecting the structure with a robotic device to identify a structural defect in the structure, generating a tool path for repairing the structural defect, and transmitting the tool path to the robotic device from a location remote from the robotic device.

Abstract: A method and apparatus for customizing tool paths. A reference tool path is identified for a tool based on an expected shape for a surface of an object. Offset data is generated for a plurality of sample points identified for use in evaluating the surface of the object. The offset data identifies a difference between the expected shape for the surface of the object and an actual shape of the surface of the object. The reference tool path is modified using the offset data to form a modified tool path for the tool.

Abstract: A method and apparatus may be present for inspecting an object. A plurality of locations associated with a plurality of operations performed by a tool on the object may be tracked. The plurality of locations is tracked while the plurality of operations is performed on the object. A path for the tool may be mapped using the plurality of locations to form a tool path. The tool path may be compared to a model of the object.