Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: Apparatuses for forming a composite structure are configured to provide a tension at least partially along at least one ply of material as the at least one ply of material is supplied from a material feed assembly to a tool.

Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.

Abstract: Apparatuses for forming a composite structure are configured to provide a tension at least partially along at least one ply of material as the at least one ply of material is supplied from a material feed assembly to a tool.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.

Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: Apparatuses, systems and methods for forming elongated composite structural members are provided. One disclosed method includes providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. A plurality of plies of fiber material preimpregnated with a thermosetting resin are laid up and pressed onto the mandrel, Pressing the plies of material may include passing one or more rollers over the mandrel and over the plurality of plies along a length of the mandrel. The roller or rollers may be at least partially complementary in shape with the mandrel while maintaining the plies of material in a substantially uncured state during the pressing. The method may include sequentially passing a plurality of rollers over the mandrel and the plies of material. The method may also include configuring a first roller to partially complementarily engage the mandrel and configuring another roller to substantially fully complementarily engage the mandrel.

Abstract: Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Abstract: A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at 17.5 to 27.5 degrees in relation to an edge of the ply layer.

Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.

Abstract: A composite structure is provided. In one embodiment, the structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation and the curved elongated member has a defined length. The curved elongated member further has a cross-sectional geometry that varies along the length.

Abstract: Methods of forming an elongated composite structural member are provided. One method includes, providing a substantially elongated mandrel having an exterior surface exhibiting a desired geometry. Laying up a first ply of preimpregnated fiber reinforced material over the mandrel. Applying a force to the first ply to establish a desired amount of tension within the first ply and then pressing the first ply onto the mandrel in a conformal manner. This includes passing at least one roller over the mandrel and the first ply while maintaining the desired amount of tension within the first ply. The at least one roller is at least partially complementary in shape with the mandrel.

Abstract: Method of forming a curved composite structure are provided. In one embodiment, the method includes contacting at least one ply of preimpregnated material on a first surface of a curved mandrel. The first surface of the mandrel has a first radius of curvature. The mandrel further has at least one second surface that has a second radius of curvature. A tension gradient is introduced on the ply adjacent to the first radius of curvature and the ply is then pressed over the curved mandrel to form the curved composite structure.

Abstract: A method and apparatus are provided for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. An apparatus may include a base with a substantially elongated mandrel mounted thereon. One or more rollers configured to at least partially complementarily engage the mandrel are configured to roll over and press one or more plies of composite material onto the mandrel. The mandrel may be disposed on a rotary table and configured to exhibit a curved elongated geometry to form at least partially curved or arcuate elongated members. The present invention enables the formation of elongated structural members from resin impregnated materials while maintaining the materials in a substantially uncured state. The formed members may then be cocured with a skin or other composite structure.

Abstract: A composite structure is provided. In one embodiment, the structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation and the curved elongated member has a defined length. The curved elongated member further has a cross-sectional geometry that varies along the length.