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: 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: An apparatus for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. The 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 a plurality of plies of composite material onto the mandrel. The rollers may be configured to form intermediate structures which partially conform to the geometry of the mandrel prior to forming the final structure, which substantially completely conforms to the geometry of the mandrel. The rollers serve to both form and debulk the structure. 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 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 method and apparatus 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 configure to roll over and press a plurality of plies of composite material onto the mandrel. The rollers may be configured to form intermediate structures which partially conform to the mandrel prior to forming the final structure which substantially completely conforms to the geometry of the mandrel. The rolls serve to both form and debulk the structure. 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 method and apparatus for the manufacture of fiber reinforced structures including the tooling and its use in the manufacture of reinforced structures. The apparatus comprises a conformable locating aperture system (CLAS) used for the formation of composite structures. The method includes the use in the formation of a structure and the method of manufacture of a structure.

Abstract: Method and apparatus for the manufacture of fiber reinforced structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling and during the curing of the fiber elements.

Abstract: A method and apparatus for the manufacture of fiber reinforced structures. The tooling and its use for the manufacture of reinforced structures is described and illustrated.

Abstract: Method and apparatus for the manufacture of fiber reinforced structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling and during the curing of the fiber elements. Method and apparatus for the manufacture of fiber reinforced structures.