Abstract: A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.

Abstract: A method apparatus, and system method for manufacturing a composite part. A set of composite preforms is placed on a set of slip sheets. The set of slip sheets with the set of composite preforms is attached to a cure mandrel to form a composite preform assembly.

Abstract: Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Abstract: Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Abstract: A method of forming a composite part from a mufti-ply prepreg composite charge comprises reducing pressure inside a bladder, located in a chamber that is at atmospheric pressure, below the atmospheric pressure. The method also comprises placing the multi-ply prepreg composite charge, having a first shape, in the chamber and reducing pressure inside the chamber below the atmospheric pressure. The method additionally comprises, while maintaining pressure inside the chamber below the atmospheric pressure, expanding the bladder within the chamber by increasing pressure inside the bladder to the atmospheric pressure, so that the multi-ply prepreg composite charge is compressed between the bladder and a forming tool, which is located inside the chamber, and the multi-ply prepreg composite charge is configured by the forming tool to a second shape, different from the first shape. The method also comprises curing the multi-ply prepreg composite charge, having the second shape.

Abstract: A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.

Abstract: A composite charge positioning assembly configured to position a composite charge onto a forming tool is presented. The composite charge positioning assembly comprises a base; a first charge support arm associated with the base and movable in a first direction towards or away from the base; and a second charge support arm associated with the base and movable in the first direction. The first charge support arm has a first surface configured to contact a portion of a composite charge. The second charge support arm has a second surface configured to contact a second portion of the composite charge.

Abstract: An illustrative embodiment of the present disclosure provides a method. A composite charge is placed over a forming and cure mandrel, a first radius filler, and a second radius filler. Mechanical pressure is applied to shape the composite charge to the forming and cure mandrel and a rigid base to form a stringer layup having a hat-shaped cross-section. Vacuum pressure is applied to the stringer layup to form a compacted stringer package.

Abstract: An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Abstract: A radius filler material positioned at an intersection of a mandrel and a placement surface is heated to form a heated radius filler material. Mechanical pressure is applied to the heated radius filler material to shape the heated radius filler material to a shaped radius filler having a desired shape against a radius of the mandrel. A composite ply is applied over the mandrel and the shaped radius filler.

Abstract: A composite charge positioning assembly configured to position a composite charge onto a forming tool is presented. The composite charge positioning assembly comprises a base; a first charge support arm associated with the base and movable in a first direction towards or away from the base; and a second charge support arm associated with the base and movable in the first direction. The first charge support arm has a first surface configured to contact a portion of a composite charge. The second charge support arm has a second surface configured to contact a second portion of the composite charge.

Abstract: A radius filler material positioned at an intersection of a mandrel and a placement surface is heated to form a heated radius filler material. Mechanical pressure is applied to the heated radius filler material to shape the heated radius filler material to a shaped radius filler having a desired shape against a radius of the mandrel. A composite ply is applied over the mandrel and the shaped radius filler.

Abstract: A composite laminate such as a hat-type stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

Abstract: An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

Abstract: An illustrative embodiment of the present disclosure provides a method. A composite charge is placed over a forming and cure mandrel, a first radius filler, and a second radius filler. Mechanical pressure is applied to shape the composite charge to the forming and cure mandrel and a rigid base to form a stringer layup having a hat-shaped cross-section. Vacuum pressure is applied to the stringer layup to form a compacted stringer package.

Abstract: A composite laminate such as a hat-type stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.