Abstract: A powder removal assembly includes a build module comprising module sidewalls and a moveable build plate slidably coupled to the module sidewalls, and an extraction housing removably engaged with the module sidewalls of the build module and defining a turbulence chamber between the build module and the extraction housing. The extraction housing includes one or more sidewalls comprising one or more sidewall fluid flow channels extending through the one or more sidewalls and a top wall coupled to the one or more sidewalls, wherein the one or more sidewall fluid flow channels extend from a position proximate a base of the one or more sidewalls to the top wall.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation system is provided that comprises an automated machine having an arm, and a ply manipulation tool attached to the arm of the automated machine. The ply manipulation tool includes a first shuttle including a first gripper, a second shuttle including a second gripper, and an actuator. The ply manipulation system further comprises a processor that automatically controls the actuator to move the first and second shuttles linearly with respect to one another to adapt the first and second grippers to a ply shape. In another embodiment, the first and second shuttles include one or more clamping elements moveable to a position to be deployed outside a perimeter of the ply. Methods for removing a ply from a sheet of material using a ply manipulation tool also are provided.

Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation tool module is provided that comprises a first shuttle including a first gripper and a first clamping element, and a second shuttle including a second gripper and a second clamping element. The first and second shuttles move with respect to one another along a path to position the first and second grippers to grip a ply and to position the first and second clamping elements outside the ply. In a particular embodiment, the ply manipulation tool module includes a lead screw and nut assemblies, the nut assemblies moving along the lead screw to position one or more grippers for gripping components. Ply manipulation tool assemblies comprising at least two modules also are provided.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: A gas turbine engine composite article having a composite article airfoil extending outwardly to an article root to an article airfoil tip. Within the article airfoil is a core including a core airfoil attached to a core root including a core dovetail. A continuous outer three-dimensional braided layer including braided composite material tows are braided on the core and the braided layer covers the entire core airfoil and the core root. The core may be an inflatable mandrel or a composite core made of a composite material. The core may include stiffeners such as an I beam or hollow rectangular cross-section box beams. A method for making such an article includes braiding a continuous outer three-dimensional braided layer including braided composite material tows on the core including covering the entire core airfoil and the core root with the continuous outer three-dimensional braided layer.

Abstract: A method and an automatic layup system for making a stack of a plurality of composite plies are presented. The automatic layup system includes a stacking assembly located in a first plane and a layup tool located in a second plane parallel to the first plane. The stacking assembly and the layup tool are movable towards each other. The method includes the steps of (a) providing one or more composite sheets between the layup tool and the stacking assembly, (b) generating a first composite ply from the one or more composite sheets, (c) placing the first composite ply on the layup tool by the stacking assembly by bringing the stacking assembly and the layup tool close to each other, and (d) repeating the steps (b) and (c) for generating and placing a second composite ply on the first composite ply, which is placed on the layup tool.

Abstract: An end effector is provided that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones having a non-smooth portion for distributing a vacuum, and a plurality of openings defined over the non-smooth portion for distributing the vacuum on the gripping surface using the vacuum source. The plurality of gripping surfaces is generally arranged in a polygonal shape. The plurality of vacuum zones are generally configured to grip cut-outs having a plurality of shapes.

Abstract: An end effector is provided that includes a vacuum source and a plurality of gripping surfaces with each gripping surface including a plurality of vacuum zones having a non-smooth portion for distributing a vacuum, and a plurality of openings defined over the non-smooth portion for distributing the vacuum on the gripping surface using the vacuum source. The plurality of gripping surfaces is generally arranged in a polygonal shape. The plurality of vacuum zones are generally configured to grip cut-outs having a plurality of shapes. Methods are also provided for removing a cut-out from a sheet of material using an end effector having a plurality of gripping surfaces.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: A layup system for use in forming a composite layup structure from a plurality of plies of composite material, wherein an outermost ply of composite material has a removable film adhered thereto. The system includes a robotic device and an end effector coupled to the robotic device. The end effector includes a layer of compressible material configured to compress the plurality of plies of composite material together when positioned over the composite layup structure. The end effector further includes a first suction device configured to grip the removable film adhered to the outermost ply of composite material. The robotic device is configured to translate the end effector relative to the composite layup structure such that the removable film is peeled from the outermost ply of composite material while the first suction device grips the removable film.

Abstract: A layup system for use in forming a composite layup structure from a plurality of plies of composite material, wherein an outermost ply of composite material has a removable film adhered thereto. The system includes a robotic device and an end effector coupled to the robotic device. The end effector includes a layer of compressible material configured to compress the plurality of plies of composite material together when positioned over the composite layup structure. The end effector further includes a first suction device configured to grip the removable film adhered to the outermost ply of composite material. The robotic device is configured to translate the end effector relative to the composite layup structure such that the removable film is peeled from the outermost ply of composite material while the first suction device grips the removable film.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation system is provided that comprises an automated machine having an arm, and a ply manipulation tool attached to the arm of the automated machine. The ply manipulation tool includes a first shuttle including a first gripper, a second shuttle including a second gripper, and an actuator. The ply manipulation system further comprises a processor that automatically controls the actuator to move the first and second shuttles linearly with respect to one another to adapt the first and second grippers to a ply shape. In another embodiment, the first and second shuttles include one or more clamping elements moveable to a position to be deployed outside a perimeter of the ply. Methods for removing a ply from a sheet of material using a ply manipulation tool also are provided.

Abstract: Various adaptive apparatus and systems for automated handling of components such as composite plies are provided. In one embodiment, a ply manipulation tool module is provided that comprises a first shuttle including a first gripper and a first clamping element, and a second shuttle including a second gripper and a second clamping element. The first and second shuttles move with respect to one another along a path to position the first and second grippers to grip a ply and to position the first and second clamping elements outside the ply. In a particular embodiment, the ply manipulation tool module includes a lead screw and nut assemblies, the nut assemblies moving along the lead screw to position one or more grippers for gripping components. Ply manipulation tool assemblies comprising at least two modules also are provided.

Abstract: A method and an automatic layup system for making a stack of a plurality of composite plies are presented. The automatic layup system includes a stacking assembly located in a first plane and a layup tool located in a second plane parallel to the first plane. The stacking assembly and the layup tool are movable towards each other. The method includes the steps of (a) providing one or more composite sheets between the layup tool and the stacking assembly, (b) generating a first composite ply from the one or more composite sheets, (c) placing the first composite ply on the layup tool by the stacking assembly by bringing the stacking assembly and the layup tool close to each other, and (d) repeating the steps (b) and (c) for generating and placing a second composite ply on the first composite ply, which is placed on the layup tool.

Abstract: A wind turbine blade includes a first shell member including a first mating surface along a first edge of the wind turbine blade. Also, the wind turbine blade includes a second shell member including a second mating surface along the first edge of the wind turbine blade, wherein the second mating surface is opposite to the first mating surface. Further, the wind turbine blade includes a bonding material disposed between the first mating surface and the second mating surface and configured to bond the first mating surface to the second mating surface. Moreover, the wind turbine blade includes a constrainer positioned at a desired bond line and coupled to one of the first mating surface and the second mating surface, wherein the constrainer is configured to restrict the bonding material from migrating into an interior cavity of the wind turbine blade.

Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

Abstract: A method for applying at least one ply onto a tool or an uncured composite layup disposed on the tool includes automatically controlling slidably removing at least one nonstick separator relative to the at least one ply positioned on the at least one nonstick separator to inhibit at least a portion of the at least one ply from adhering to the tool or uncured composite layup while applying a moving compressive force to an outer surface of the at least one ply relative to a moving trailing edge of the at least one nonstick separator to adhere at least a portion of the at least one ply to the tool or to the uncured composite layup.

Abstract: A gas turbine engine composite article having a composite article airfoil extending outwardly to an article root to an article airfoil tip. Within the article airfoil is a core including a core airfoil attached to a core root including a core dovetail. A continuous outer three-dimensional braided layer including braided composite material tows are braided on the core and the braided layer covers the entire core airfoil and the core root. The core may be an inflatable mandrel or a composite core made of a composite material. The core may include stiffeners such as an I beam or hollow rectangular cross-section box beams. A method for making such an article includes braiding a continuous outer three-dimensional braided layer including braided composite material tows on the core including covering the entire core airfoil and the core root with the continuous outer three-dimensional braided layer.

Abstract: A wind turbine blade includes a first shell member including a first mating surface along a first edge of the wind turbine blade. Also, the wind turbine blade includes a second shell member including a second mating surface along the first edge of the wind turbine blade, wherein the second mating surface is opposite to the first mating surface. Further, the wind turbine blade includes a bonding material disposed between the first mating surface and the second mating surface and configured to bond the first mating surface to the second mating surface. Moreover, the wind turbine blade includes a constrainer positioned at a desired bond line and coupled to one of the first mating surface and the second mating surface, wherein the constrainer is configured to restrict the bonding material from migrating into an interior cavity of the wind turbine blade.