Abstract: A method for fabricating a preform for a portion of an aircraft includes acquiring a sheet of broad good fiber reinforced material, trimming the sheet to form layup pieces having boundaries, placing the boundaries into alignment, arranging the layup pieces in a layup pattern to form a ply, performing a placement operation that transports the layup pattern onto a layup mandrel, and shaping the layup pattern into conformance with a contour of the layup mandrel.

Abstract: Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.

Abstract: Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.

Abstract: Apparatus and methods are provided for fabrication of a structure, for example, a half barrel section of a fuselage. The apparatus includes an indexing unit dimensioned for coupling to an indexing feature disposed on the structure. The structure proceeds along a process direction during fabrication. A cutting station cuts out manufacturing excess from the structure to form, for example, openings for windows and doors. A method for fabrication of a structure includes indexing a structure to a cutting station based on an indexing feature associated or located on the structure. The method includes operating the cutting station to cut manufacturing excess from the structure. A method includes removing cut sections of the manufacturing excess and routing these sections away from the cutting station.

Abstract: Systems and methods are provided for assembling aircraft fuselages. One embodiment is a method for assembling a fuselage of an aircraft. The method includes indexing an arcuate section of a fuselage to a frame installation station, feeding a frame at the frame installation station into a concavity defined by the arcuate section, placing the frame against an Inner Mold Line (IML) of the arcuate section while the frame is within the concavity, and affixing the frame to the arcuate section.

Abstract: Systems and methods are provided for applying fasteners to a structure. One embodiment is a method that includes disposing a first set of end effectors along a fixed inner track that follows an Inner Mold Line (IML) of a structure, disposing a second set of end effectors along a fixed outer track that follows an Outer Mold Line (OML) of the structure, aligning a first end effector at the fixed inner track with a second end effector at the fixed outer track, clamping the structure between the first end effector and the second end effector, by pressing the first end effector and the second end effector into the structure, and applying a fastener to the structure.

Abstract: Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.

Abstract: Systems and methods are provided for fabricating a wing panel. Methods include aligning a strongback over a wing panel, vacuum attaching a wing panel surface and pogos extending beneath the strongback, and adjusting the length of pogos to enforce a contour to the wing panel. Systems include a strongback to extend over a wing panel, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Other systems include a track, work stations along the track, a strongback to extend over the wing panel and move along the track, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Apparatus includes a shuttle having adapters that mate the shuttle with a track, adjustable-length carriers with vacuum couplers to couple with a wing panel surface, and indexing units that interact with indexing features in a manufacturing excess of the wing panel.

Abstract: Systems and methods are provided for fabricating a wing panel. Methods include aligning a strongback over a wing panel, vacuum attaching a wing panel surface and pogos extending beneath the strongback, and adjusting the length of pogos to enforce a contour to the wing panel. Systems include a strongback to extend over a wing panel, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Other systems include a track, work stations along the track, a strongback to extend over the wing panel and move along the track, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Apparatus includes a shuttle having adapters that mate the shuttle with a track, adjustable-length carriers with vacuum couplers to couple with a wing panel surface, and indexing units that interact with indexing features in a manufacturing excess of the wing panel.

Abstract: Systems, methods, and apparatus are provided for assembling a wing. Methods include coupling a robot arm to a bracket on a rib held against a wing panel, and operating the coupled robot arm to install shims between the rib and wing panel. Some methods further include mounting (e.g. detachably) the bracket, such as by aligning it with indexing features at the rib. In some methods, the bracket enforces a contour to the rib. Systems include a carriage coupled to a rib, and a robot arm extending therefrom that is operable to perform work (e.g. inspection, installing shims and/or fasteners, etc.) at an interface between the rib and a wing panel. Apparatus includes a robot arm dimensioned for placement at an interface between a rib and a wing panel, with the robot arm including an end effector to perform work upon the interface (e.g. inspection, installing shims and/or fasteners, etc.).

Abstract: Systems and methods are provided for placing preforms onto a mandrel. One illustrative method includes moving a mandrel in a process direction relative to a station(s) that comprises multiple pick-and-place machine(s), identifying a tray that stores a preform comprising an unhardened fiber-reinforced material, placing the strong back at the preform via at least one of the pick-and-place machine(s), applying a vacuum to hold the preform in contact with the strong back, transporting the preform to a mandrel via the pick-and-place machine(s), and placing the preform onto the mandrel.

Abstract: Systems and methods are provided for assembling an aircraft. The method includes receiving an upper half barrel section of fuselage that is in a crown up orientation and installing a crown module into the upper half barrel section.

Abstract: Systems and methods are provided for assembling an airframe of an aircraft, including receiving a half barrel section of fuselage, advancing the half barrel section in a process direction across multiple stations to separately and simultaneously perform work on the half barrel sections, and subsequently joining the half barrel segments to form a section of the airframe. Each pair of half barrel sections, such as upper and lower half barrels, are progressed through assembly line processes to be delivered to a joining station for joining the half barrels together to form a circumferential section of the fuselage. Multiple joined circumferential sections are joined together to form an elongated extent of the fuselage. Indexing features are provided in the assembly process to monitor and control the progression of the half barrel sections in the work stations of the assembly line process.

Abstract: Systems and methods are provided for assembly line processing of aircraft wing panels. The method includes inputting wing panels into an assembly line, the assembly line having a number of work stations, the wing panels oriented such that leading edges are all on a first side of the work stations, and trailing edges are all on a second side of the work stations, and advancing the wing panels in a process direction through the number of work stations, at least a first portion of the work stations dedicated to wing panel leading edge processing, and a second portion of the work stations dedicated to wing panel trailing edge processing.

Abstract: Systems and methods are provided for assembling a section of a fuselage of an aircraft. The method includes pulsing a half barrel section of the fuselage along a track in a process direction, utilizing an indexing feature associated with the half barrel section to determine a desired contour for a portion of the half barrel section, and enforcing the desired contour onto the half barrel section using components that enforce an inner mold line and components that enforce an outer mold line when the half barrel section is out of tolerance from the desired contour.

Abstract: Systems and methods are provided for aircraft assembly. The method includes receiving a half barrel section of fuselage in an assembly line having a plurality of serially arranged work stations; advancing the half barrel section in a process direction through the assembly line such that the half barrel section extends across at least a portion of the work stations; and performing work on the half barrel section with the portion of the work stations simultaneously.

Abstract: Methods and apparatus involved in the process of hardening a composite part are disclosed herein. The methods include applying a preform to a mandrel, covering the preform with a caul plate, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel and hardening the preform into a composite part while the caul plate is held against the preform. The apparatus include a mandrel, a caul plate which defines a surface of a preform and where the caul plate may include a rigid material and seals disposed between the mandrel and the caul plate. In an additional aspect, the apparatus may include a sealed chamber with a mandrel and a caul plate and a circumferential seal between the mandrel and the caul plate.

Abstract: A flatbed, step-deck, double-drop deck, or lowboy trailer assembly comprises a plurality of metal crossmembers extending in a transverse direction of the trailer assembly; a metal deck supported by the plurality of crossmembers, the metal deck having an upper deck surface and a lower deck surface; and a pair of parallel wooden boards extending in a longitudinal direction of the trailer assembly proximate respective laterally opposite sides of the trailer assembly. Each wooden board in the pair of wooden boards is located in a respective recessed portion of the metal deck. The lower deck surface is situated between and separates a lower surface of each wooden board from the plurality of metal cross members. The lower deck surface is welded to the plurality of crossmembers.

Abstract: A method for forming a resonating structure within a body lumen, the method including advancing a flexible microwave catheter into a body lumen of a patient, the flexible microwave catheter including a radiating portion at the distal end of the flexible microwave catheter, the radiating portion configured to receive microwave energy, and at least one centering device proximate the radiating portion configured to deploy radially outward from the flexible microwave catheter; positioning the radiating portion near tissue of interest; deploying the at least one centering device radially outward from the flexible microwave catheter within the body lumen such that a longitudinal axis of the radiating portion is substantially parallel with and at a fixed distance from a longitudinal axis of the body lumen near the targeted tissue; and delivering microwave energy to the radiating portion such that a circumferentially balanced resonating structure is formed with the body lumen.

Abstract: The present disclosure includes a method of providing a virtual bottle service from an establishment to a user. The virtual bottle service is accessible by the user via an app on a smartphone of a user. The method comprises receiving, via the app on the smartphone of a user, a purchase request for a virtual bottle from an establishment, and after the receiving, allocating the user with a predetermined number of drinks of a particular liquor from the establishment. The method further includes, in response to a drink order from the virtual bottle by the user, decrementing the number of drinks from the virtual bottle that remain available to the user. The method may also include communicating, to the user, the remaining number of drinks via the app on the smartphone. A corresponding system that incorporates and/or uses such a method is also provided.