Abstract: A method for aligning and joining a first structure to a second structure in an aircraft is provided. A spacer system having a shape memory alloy is positioned in a gap between the first structure and the second structure. The shape memory alloy is initially in a cooled state. A temperature of the shape memory alloy is increased such that the shape memory alloy changes from the cooled shape to a heated shape to fill the gap and apply a load to hold the first structure in place relative to the second structure. Additional processes may then be performed to join the first structure to the second structure.

Abstract: A method for aligning and joining a first structure to a second structure in an aircraft is provided. A spacer system having a shape memory alloy is positioned in a gap between the first structure and the second structure. The shape memory alloy is initially in a cooled state. A temperature of the shape memory alloy is increased such that the shape memory alloy changes from the cooled shape to a heated shape to fill the gap and apply a load to hold the first structure in place relative to the second structure. Additional processes may then be performed to join the first structure to the second structure.

Abstract: Methods of assembling a stiffened composite structure include loading, with a stiffener loading tool, a respective stiffener from a supply of stiffeners onto an inner mold line layup mandrel; repeating the loading to load a plurality of stiffeners onto the inner mold line layup mandrel; and following the repeating, affixing a respective skin segment from a supply of skin segments to the plurality of stiffeners loaded on the inner mold line layup mandrel to form at least a portion of the stiffened composite structure. Systems for assembling stiffened composite structures include a supply of stiffeners; an inner mold line layup mandrel; and a stiffener loading tool configured to load the respective stiffener onto the inner mold line layup mandrel.

Abstract: Systems and methods for assembling a skin of a composite structure on an outer surface of an inner mold line layup mandrel. The systems and methods include receiving a plurality of ply kits, assembling the plurality of ply kits to form a skin segment that defines a portion of the skin, and affixing the skin segment to the outer surface of the layup mandrel. The assembling includes transferring a respective ply kit of the plurality of ply kits to a non-planar transfer tool, compacting the respective ply kit on the non-planar transfer tool, and repeating the transferring and the compacting for each ply kit in the plurality of ply kits to form the skin segment.

Abstract: Systems and methods for assembling a skin of a composite structure on an outer surface of an inner mold line layup mandrel. The systems and methods include receiving a plurality of ply kits, assembling the plurality of ply kits to form a skin segment that defines a portion of the skin, and affixing the skin segment to the outer surface of the layup mandrel. The assembling includes transferring a respective ply kit of the plurality of ply kits to a non-planar transfer tool, compacting the respective ply kit on the non-planar transfer tool, and repeating the transferring and the compacting for each ply kit in the plurality of ply kits to form the skin segment.