Abstract: A method for pelletizing an extruded material with an extruding nozzle includes inserting the extruded material into the extruding nozzle so that the extruded material flows through at least one material-flow channel, extending through a radiator of the extruding nozzle. Heat is transferred between the extruded material, flowing through the at least one material-flow channel, and the radiator. At least a portion of the radiator is located within a housing of the extruding nozzle.

Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

Abstract: A roller for automated fiber placement includes a flexible rim member arranged about a central axis. The flexible rim member has an inner side and an outer side, and the central axis is closer to the inner side than to the outer side. The roller also includes a hub member arranged substantially concentric with the flexible rim member about the central axis. The hub member defines an opening to receive a shaft of an automated fiber placement machine. The roller further includes a plurality of curved interconnect members extending between the hub member and the flexible rim member. Each of the plurality of curved interconnect members is elastically deformable to accommodate deformation of the flexible rim member. The roller also includes one or more roller skin layers coupled to the outer side of the flexible rim member.

Abstract: A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface and a collapsible support having a support surface. The collapsible support is configured to transition from an extended conformation to a collapsed conformation and is configured such that a gap width of a gap between the support surface and the forming surface decreases during the transition. The methods include positioning a composite charge, transitioning the collapsible support from an extended conformation to a collapsed conformation, decreasing the gap width of the gap as the collapsible support transitions from the extended conformation to the collapsed conformation, and deforming the composite charge from an initial conformation to a final conformation.

Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface and a collapsible support having a support surface. The collapsible support is configured to transition from an extended conformation to a collapsed conformation and is configured such that a gap width of a gap between the support surface and the forming surface decreases during the transition. The methods include positioning a composite charge, transitioning the collapsible support from an extended conformation to a collapsed conformation, decreasing the gap width of the gap as the collapsible support transitions from the extended conformation to the collapsed conformation, and deforming the composite charge from an initial conformation to a final conformation.

Abstract: Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface configured to receive the composite charge and a collapsible support having a support surface. The forming surface has a forming surface edge that extends along a length of the forming surface, and the support surface has a die-proximate support surface edge that extends along the length of the support surface. The forming surface edge and the die-proximate support surface edge define a gap therebetween. A shape of the die-proximate support surface edge corresponds to a shape of the forming surface edge such that a gap width of the gap is at least substantially constant along a length of the gap. The collapsible support is configured to transition from an extended conformation to a collapsed conformation. The methods include methods of utilizing the systems.

Abstract: A method for pelletizing an extruded material with an extruding nozzle includes inserting the extruded material into the extruding nozzle so that the extruded material flows through at least one material-flow channel, extending through a radiator of the extruding nozzle. Heat is transferred between the extruded material, flowing through the at least one material-flow channel, and the radiator. At least a portion of the radiator is located within a housing of the extruding nozzle.

Abstract: An extruding nozzle is provided. The extruding nozzle includes a housing and a radiator. The radiator is at least partially disposed within the housing. The extruding nozzle also includes at least one material flow channel. The at least one material flow channel is at least partially disposed within the housing and extends through the radiator.

Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Abstract: An extruding nozzle is provided. The extruding nozzle includes a housing and a radiator. The radiator is at least partially disposed within the housing. The extruding nozzle also includes at least one material flow channel. The at least one material flow channel is at least partially disposed within the housing and extends through the radiator.

Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Abstract: A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Abstract: Systems and methods of forming a skin for a composite structure and composite structures including the same. The systems and methods include operatively attaching a charge of composite material to a flexible substrate to define a composite-substrate assembly. The systems and methods further include deforming the composite-substrate assembly by conforming the composite-substrate assembly to a non-planar pre-forming surface of a pre-forming mandrel to define a non-planar skin surface contour on the charge of composite material. The systems and methods further include maintaining the charge of composite material in tension in a direction that is parallel to an interface between the charge of composite material and the flexible substrate during the deforming.

Abstract: Devices, systems and methods for compacting a charge of composite material across an edge are disclosed herein. The devices include a vacuum compaction device including a compaction force transfer structure, a sealing structure, and a vacuum distribution manifold. The compaction force transfer structure includes a first barrier structure, a second barrier structure, and a junction support that extends at least partially between the first barrier structure and the second barrier structure. The junction support is configured to maintain the first barrier structure and the second barrier structure at an angle with respect to one another and to permit limited angular motion of the first barrier structure and the second barrier structure relative to one another. The systems include composite structure fabrication systems that include the vacuum compaction device. The methods include methods of operating the vacuum compaction device.

Abstract: Systems, methods, and vacuum chucks for transferring flexible elongate bodies are disclosed herein. The vacuum chucks include an elongate rigid support, a vertically oriented vacuum surface, a vacuum manifold, and a skirt seal. The systems include an elongate horizontal support structure, a transfer structure, a plurality of vertical linkages, which are operatively attached to the elongate horizontal support structure, and a plurality of vacuum chucks. Each of the plurality of vacuum chucks is operatively attached to a respective one of the plurality of vertical linkages. The methods include suspending an elongate horizontal support structure with a transfer structure, aligning each of a plurality of vacuum chucks with a respective portion of a vertical surface of a flexible elongate body, selectively actuating each of the plurality of vacuum chucks to retain the respective portion of the vertical surface of the flexible elongate body, and lifting the flexible elongate body.

Abstract: A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Abstract: Devices, systems and methods for compacting a charge of composite material across an edge are disclosed herein. The devices include a vacuum compaction device including a compaction force transfer structure, a sealing structure, and a vacuum distribution manifold. The compaction force transfer structure includes a first barrier structure, a second barrier structure, and a junction support that extends at least partially between the first barrier structure and the second barrier structure. The junction support is configured to maintain the first barrier structure and the second barrier structure at an angle with respect to one another and to permit limited angular motion of the first barrier structure and the second barrier structure relative to one another. The systems include composite structure fabrication systems that include the vacuum compaction device. The methods include methods of operating the vacuum compaction device.

Abstract: Systems and methods for assembling a skin of a composite structure are disclosed herein. The methods include operatively attaching a charge of composite material to a flexible substrate to define an initial conformation for a composite-substrate assembly and locating the composite-substrate assembly and a layup mandrel proximal to one another. The methods further include pressing the composite-substrate assembly against an outer surface of the layup mandrel to deform the composite-substrate assembly to a final conformation. The methods also include affixing the charge of composite material to the outer surface of the layup mandrel and releasing the charge of composite material from the flexible substrate while retaining the charge of composite material on the outer surface of the layup mandrel. The systems include the flexible substrate, the layup mandrel, and an assembly deformation structure that is configured to press the composite-substrate assembly against the outer surface of the layup mandrel.