Abstract: A manufacture and process for a winglet formed as a unitary structure by laying up and co-curing three ply-sets in a bifurcated configuration, without metal and fasteners, comprising three continuous surfaces: a first ply-set comprising a first continuous surface forming: an outboard surface of an upper blade; an outboard portion of a root region; and an outboard surface of a lower blade; a second ply-set forming a second continuous surface forming an inboard surface of the upper blade and an upper skin of the root region; and a third ply-set forming a third continuous surface forming an inboard surface of the lower blade and a lower skin of the root region . . . continuous surface. The root region being integral in the bifurcated configuration, matching a shape of an airfoil of a tip of a wing, and comprising two supports that comprise an additional ply-set shaped to receive an attachment system.

Abstract: A vacuum bagging diaphragm assembly used in forming a component from composite material includes a first sheet of a first material. Also included is a second sheet of a second material for positioning between a three dimensional forming tool and the first sheet. A modulus of elasticity of the second material is greater than a modulus of elasticity of the first material. A method includes a step of positioning a composite laminate material between a first sheet of a first material and a second sheet of a second material. The second material has a modulus of elasticity greater than a modulus of elasticity of the first material. The method further includes a step of positioning the second material of the second sheet in overlying relationship to a three dimensional forming tool with the second material positioned between the three dimensional forming tool and the composite material.

Abstract: A method includes the step placing composite laminate material onto a three dimensional forming tool with an external surface and at least four junctures associated with the external surface. Each juncture is positioned between two adjacent planar surfaces in which each of the two adjacent surfaces extend in a different plane, the junctures converge and each juncture defines a line of direction. The three dimensional forming tool arranged in a two dimensional pattern, has the lines of direction and the two adjacent planar surfaces positioned on opposing sides of each of the at least four junctures are all positioned in a common plane. The line of direction of each of the at least four junctures in the two dimensional pattern converge to a common point. At least one line of direction is not in alignment beyond the common point with another line of direction. Tool apparatus is also provided.

Abstract: A vacuum bagging diaphragm assembly used in forming a component from composite material includes a first sheet of a first material. Also included is a second sheet of a second material for positioning between a three dimensional forming tool and the first sheet. A modulus of elasticity of the second material is greater than a modulus of elasticity of the first material. A method includes a step of positioning a composite laminate material between a first sheet of a first material and a second sheet of a second material. The second material has a modulus of elasticity greater than a modulus of elasticity of the first material. The method further includes a step of positioning the second material of the second sheet in overlying relationship to a three dimensional forming tool with the second material positioned between the three dimensional forming tool and the composite material.

Abstract: A method includes the step placing composite laminate material onto a three dimensional forming tool with an external surface and at least four junctures associated with the external surface. Each juncture is positioned between two adjacent planar surfaces in which each of the two adjacent surfaces extend in a different plane, the junctures converge and each juncture defines a line of direction. The three dimensional forming tool arranged in a two dimensional pattern, has the lines of direction and the two adjacent planar surfaces positioned on opposing sides of each of the at least four junctures are all positioned in a common plane. The line of direction of each of the at least four junctures in the two dimensional pattern converge to a common point. At least one line of direction is not in alignment beyond the common point with another line of direction. Tool apparatus is also provided.

Abstract: A method and apparatus for forming a winglet formed as a one-piece composite for an aircraft is presented. The winglet comprises a first blade, a second blade, and a root region. The first blade includes a first leading edge and a first trailing edge. The second blade includes a second leading edge and a second trailing edge. The second blade is positioned at an angle to the first blade. The root region is co-cured with the first blade and the second blade to form the winglet. The root region is configured to receive an attachment system for attaching the winglet to a wing of the aircraft.

Abstract: A method and apparatus for forming a composite winglet for an aircraft is presented. The composite winglet comprises a first blade, a second blade, and a root region. The first blade includes a first leading edge and a first trailing edge. The second blade includes a second leading edge and a second trailing edge. The second blade is positioned at an angle to the first blade. The root region is co-cured with the first blade and the second blade to form the composite winglet. The root region is configured to receive an attachment system for attaching the composite winglet to a wing of the aircraft.

Abstract: A method and apparatus for forming a composite winglet for an aircraft is presented. The composite winglet comprises a first blade, a second blade, and a root region. The first blade includes a first leading edge and a first trailing edge. The second blade includes a second leading edge and a second trailing edge. The second blade is positioned at an angle to the first blade. The root region is co-cured with the first blade and the second blade to form the composite winglet. The root region is configured to receive an attachment system for attaching the composite winglet to a wing of the aircraft.