Abstract: Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.

Abstract: Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.

Abstract: Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.

Abstract: Methods for forming radius fillers for composite structures are disclosed herein. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.

Abstract: Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.

Abstract: Methods for forming radius fillers for composite structures are disclosed herein. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.

Abstract: Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a first support surface and a support surface edge. The systems further include a second support surface, a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.

Abstract: A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the base portion and may be formed of a plurality of substantially constant width composite plies defining a substantially constant cross-sectional shape of the keyway portion. The tip portion may be stacked on the keyway portion and may be formed of composite plies.

Abstract: A method of forming a radius filler may include providing an upper portion having substantially constant width composite plies, providing a base portion as a stack of variable width composite plies, and stacking the upper portion onto the base portion to form a radius filler stack.

Abstract: Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a first support surface and a support surface edge. The systems further include a second support surface, a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.