Abstract: Disclosed herein are a system and method for producing paint templates for painting a design on a target surface. The system includes a processor configured to generate a geo-file of paint template designs. The processor includes a design module configured to parse the design into a set of paint sub-designs and a template design module configured to generate the geo-file of paint template designs based on the set of paint sub-designs. The generated geo-file of paint template designs includes a paint template design that corresponds to a paint sub-design. The system further includes a plotter configured to produce a set of paint templates based on the geo-file of paint template designs. Each paint template design includes a set of alignment marks and each paint template is produced with a set of alignment apertures corresponding to the set of alignment marks.

Abstract: Disclosed herein are a system and method for producing paint templates for painting a design on a target surface. The system includes a processor configured to generate a geo-file of paint template designs. The processor includes a design module configured to parse the design into a set of paint sub-designs and a template design module configured to generate the geo-file of paint template designs based on the set of paint sub-designs. The generated geo-file of paint template designs includes a paint template design that corresponds to a paint sub-design. The system further includes a plotter configured to produce a set of paint templates based on the geo-file of paint template designs. Each paint template design includes a set of alignment marks and each paint template is produced with a set of alignment apertures corresponding to the set of alignment marks.

Abstract: A system for determining an optimal clocking orientation of an object at which to attach mating structure to the object includes a plurality of radiation devices, a plurality of transceivers, and a processor. The radiation devices are mounted on the object which has an as-designed object configuration. The transceivers are configured to generate distance measurements between the transceivers and the radiation devices at different clocking orientations of the object. The processor is configured to determine, based on the distance measurements, as-built object configurations corresponding to the different clocking orientations of the object. The processor is configured to compare the as-built object configurations to the as-designed object configuration and determines an optimal clocking orientation at which the as-built object configuration has the smallest deviation from the as-designed object configuration.

Abstract: A system for determining an optimal clocking orientation of an object at which to attach mating structure to the object includes a plurality of radiation devices, a plurality of transceivers, and a processor. The radiation devices are mounted on the object which has an as-designed object configuration. The transceivers are configured to generate distance measurements between the transceivers and the radiation devices at different clocking orientations of the object. The processor is configured to determine, based on the distance measurements, as-built object configurations corresponding to the different clocking orientations of the object. The processor is configured to compare the as-built object configurations to the as-designed object configuration and determines an optimal clocking orientation at which the as-built object configuration has the smallest deviation from the as-designed object configuration.

Abstract: A system for determining an optimal clocking orientation of an object at which to attach mating structure to the object includes a plurality of radiation devices mounted on an object, a plurality of transceivers configured to emit radiation toward the object, and a processor. The object potentially has a first as-built object configuration that differs from an as-designed object configuration. The transceivers continuously generate distance measurements between the transceivers and the radiation devices during rotation of the object. The processor continuously determines, based on the distance measurements, additional unique as-built object configurations corresponding to changing clocking orientations of the object during rotation.

Abstract: Methods and systems for monitoring an integrity of electrical connectivity between a repair patch and a parent structure include providing the repair patch with an embedded sensor configured to detect electrical conductivity. The repair patch includes a ply of conductive material that overlaps a portion of a conductive layer of the parent structure. A baseline set of sensor data is acquired from the sensor indicative of an electrical connectivity between the ply of conductive material of the repair patch and the conductive layer of the parent structure. One or more additional sets of data may be obtained from the sensor and compared to the baseline set of data to determine an integrity of the electrical connectivity between the ply of conductive material of the repair patch and the conductive layer of the parent structure.

Abstract: An edge stabilizer for a composite structure includes an elongate edge support segment, defining a geometric shape of an edge of the composite structure, and a connector, configured to attach the edge support segment to the edge of the composite structure. The edge support segment comprises first and second halves configured to attach together around the edge, each half including a shoulder, opposing mating relationship of the shoulders defining a slot for receiving the edge. The edge stabilizer can be part of a system for stabilizing an edge of a composite barrel section. The system can also include a moveable cart, the barrel section being supportable upon the cart.

Abstract: A system for determining an optimal clocking orientation of an object at which to attach mating structure to the object includes a plurality of radiation devices mounted on an object, a plurality of transceivers configured to emit radiation toward the object, and a processor. The object potentially has a first as-built object configuration that differs from an as-designed object configuration. The transceivers continuously generate distance measurements between the transceivers and the radiation devices during rotation of the object. The processor continuously determines, based on the distance measurements, additional unique as-built object configurations corresponding to changing clocking orientations of the object during rotation.

Abstract: A barrel assembly for a composite structure includes a barrel of composite material, a first end ring, and a mid support. The barrel of composite material has a first end, an interior surface and an outer surface, and the first end ring is removably attached to the first end. The first end ring has a perimeter that is substantially congruent with the first end, and is configured to maintain a shape of the barrel. The mid support is removably disposed within the barrel, and has a plurality of spokes extending outwardly from a central hub to contact the interior surface, to maintain a shape of the barrel.

Abstract: Methods and systems for monitoring an integrity of electrical connectivity between a repair patch and a parent structure include providing the repair patch with an embedded sensor configured to detect electrical conductivity. The repair patch includes a ply of conductive material that overlaps a portion of a conductive layer of the parent structure. A baseline set of sensor data is acquired from the sensor indicative of an electrical connectivity between the ply of conductive material of the repair patch and the conductive layer of the parent structure. One or more additional sets of data may be obtained from the sensor and compared to the baseline set of data to determine an integrity of the electrical connectivity between the ply of conductive material of the repair patch and the conductive layer of the parent structure.

Abstract: A system comprising: a parent structure made of composite material and having a repair site; a repair patch made of composite material, the repair patch being bonded to the parent structure at the repair site; and a sensor embedded in the repair patch. The system may further comprise non-volatile memory and an interface unit embedded in the repair patch and electrically connected to the sensor. In one embodiment, the sensor is a loop-shaped sensor comprising an electrically conductive structure having an electrical conductivity that varies as a function of a pressure exerted on the repair patch. In another embodiment, the sensor comprises a sensor chip having nonvolatile memory. In a further embodiment, the sensor comprises an optical fiber that is sensitive to changes in pressure on or strain in the repair patch.

Abstract: A method for monitoring structural integrity of a repaired aircraft component made of composite material. The method comprises: (a) placing a multiplicity of plies of repair composite material over a repair site on the component with a sensor disposed between two plies; (b) curing the plies of repair composite material so that the repair composite material, with the sensor embedded therein, is bonded to the repair site; (c) acquiring first sensor data from the sensor before a flight of the aircraft; (d) acquiring second sensor data from the sensor during or after the flight; (e) comparing the first sensor data to the second sensor data; (f) identifying differences between the first and second sensor data indicative of structural change; and (g) determining whether the identified differences indicate structural change in excess of a specified threshold. Steps (c) through (g) are performed by a computer system.

Abstract: A barrel assembly for a composite structure includes a barrel of composite material, a first end ring, and a mid support. The barrel of composite material has a first end, an interior surface and an outer surface, and the first end ring is removably attached to the first end. The first end ring has a perimeter that is substantially congruent with the first end, and is configured to maintain a shape of the barrel. The mid support is removably disposed within the barrel, and has a plurality of spokes extending outwardly from a central hub to contact the interior surface, to maintain a shape of the barrel.

Abstract: A barrel assembly for a composite structure includes a barrel of composite material, a first end ring, and a mid support. The barrel of composite material has a first end, an interior surface and an outer surface, and the first end ring is removably attached to the first end. The first end ring has a perimeter that is substantially congruent with the first end, and is configured to maintain a shape of the barrel. The mid support is removably disposed within the barrel, and has a plurality of spokes extending outwardly from a central hub to contact the interior surface, to maintain a shape of the barrel.

Abstract: A barrel assembly for a composite structure includes a barrel of composite material, a first end ring, and a mid support. The barrel of composite material has a first end, an interior surface and an outer surface, and the first end ring is removably attached to the first end. The first end ring has a perimeter that is substantially congruent with the first end, and is configured to maintain a shape of the barrel. The mid support is removably disposed within the barrel, and has a plurality of spokes extending outwardly from a central hub to contact the interior surface, to maintain a shape of the barrel.