Abstract: An example mandrel for processing a part is described including a plurality of elastomeric components aligned end to end and spaced apart linearly to form a segmented mandrel body, and compressible interconnections positioned within spacing between adjacent elastomeric components and abutting the adjacent elastomeric components. The compressible interconnections allow the plurality of elastomeric components to expand axially due to thermal expansion resulting in a distribution of pressure. An example method for fabricating a composite part is also described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity of the tooling surface such that the base composite layer is between the mandrel and the tooling surface, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing, and removing the mandrel from the cavity of the tooling surface.

Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.

Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.

Abstract: An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

Abstract: An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.

Abstract: An example mandrel for processing a part is described including an inner core having a material with first thermal properties, and an outer layer surrounding the inner core. The outer layer includes a material with second thermal properties different than the first thermal properties to enable uniform pressure distribution within the mandrel. An example method for fabricating a composite part is described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing the base composite layer and the skin such that during curing a pressure due to thermal expansion of one of the inner core and the outer layer is distributed by the other, and removing the mandrel from the cavity of the tooling surface following the curing.

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

Abstract: An example mandrel for processing a part is described including a plurality of elastomeric components aligned end to end and spaced apart linearly to form a segmented mandrel body, and compressible interconnections positioned within spacing between adjacent elastomeric components and abutting the adjacent elastomeric components. The compressible interconnections allow the plurality of elastomeric components to expand axially due to thermal expansion resulting in a distribution of pressure. An example method for fabricating a composite part is also described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity of the tooling surface such that the base composite layer is between the mandrel and the tooling surface, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing, and removing the mandrel from the cavity of the tooling surface.

Abstract: There is provided a forming apparatus for constraining a composite charge and forming the composite charge into a highly contoured composite structure. The forming apparatus includes a first die and a second die between which the composite charge is formed. The first die has pairs of first die portions spaced apart to define a die cavity into which the composite charge is formed into a contoured hat section having a cap. The forming apparatus includes a constraining assembly having a constraining device positioned in the die cavity. The constraining device is designed to constrain a cap portion, and to apply an upward resistive force against the cap portion, and against a downward compressive force applied by the second die, to provide wrinkle prevention in the cap as the contoured hat section is formed. The constraining assembly has a retaining element to retain the constraining device.

Abstract: A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

Abstract: A method is provided for fabricating a composite ply layup with a desired shape. The method includes moving a shuttle having a sheet of elastic material into engagement with at least one composite ply at a ply pickup station, and picking up the at least one composite ply with the shuttle. The method also includes transporting the shuttle and the at least one composite ply from the ply pickup station to a forming station, and moving the shuttle and the at least one composite ply into engagement with a forming tool at the forming station or any previously laid plies on the forming tool. The method further includes compacting the at least one composite ply on the forming tool or any previously laid plies on the forming tool with the shuttle to form the composite ply layup with the desired shape.

Abstract: An example mandrel for processing a part is described including a plurality of elastomeric components aligned end to end and spaced apart linearly to form a segmented mandrel body, and compressible interconnections positioned within spacing between adjacent elastomeric components and abutting the adjacent elastomeric components. The compressible interconnections allow the plurality of elastomeric components to expand axially due to thermal expansion resulting in a distribution of pressure. An example method for fabricating a composite part is also described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity of the tooling surface such that the base composite layer is between the mandrel and the tooling surface, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing, and removing the mandrel from the cavity of the tooling surface.

Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Abstract: A mandrel for processing a part is described that includes a solid mandrel body with an elastomeric material, and hollow micro-particles embedded within the solid mandrel body in a uniform distribution. The hollow micro-particles deform in response to a change in a processing environment resulting in a distribution of voids in the solid mandrel body. A method for fabricating a composite part is also described that includes placing a base composite layer into a cavity of a tooling surface, inserting the mandrel into the cavity, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing the base composite layer and the skin such that during curing the hollow micro-particles deform resulting in the distribution of voids in the solid mandrel body, and removing the mandrel from the cavity of the tooling surface following the curing.

Abstract: A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.

Abstract: An example apparatus for fabrication of a co-cured composite assembly includes a layup tool body with a cavity, a thermal expansion insert inserted into the cavity of the layup tool body and a first uncured composite part of the composite assembly is positioned onto the thermal expansion insert, and a solid internal mandrel configured for insertion onto the first uncured composite part. During curing, the first uncured composite part compacts and reduces in thickness while the solid internal mandrel and the thermal expansion insert each increase in size to apply pressure to the first uncured composite part.

Abstract: A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

Abstract: A method for manufacturing a cured composite structure from first stringers, second stringers and a panel comprising a first side and a second side, the method includes, for each first stringer, supporting the first stringer on the first side of the panel using a substantially rigid mandrel positioned within a first cavity defined between the first stringer and the first side of the panel, for each second stringer, supporting the second stringer on the second side of the panel using a flexible mandrel positioned within a second cavity defined between the second stringer and the second side of the panel, and co-curing the first stringers, the panel, and the second stringers while each of the one or more first stringers are supported by the respective substantially rigid mandrel and each of the one or more second stringers are supported by the respective flexible mandrel.