Abstract: A wrinkle mitigation system includes at least one tooling rod disposed against a tool surface at a location on the tool where a composite ply is configured to overlap the tooling rod. The tooling rod may has an elongated shape and is generally oriented along a direction of wrinkle formation in the composite ply. The tooling rod has a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply.

Abstract: A wrinkle mitigation system includes at least one tooling rod disposed against a tool surface at a location on the tool where a composite ply is configured to overlap the tooling rod. The tooling rod may has an elongated shape and is generally oriented along a direction of wrinkle formation in the composite ply. The tooling rod has a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply.

Abstract: A wrinkle mitigation system may include at least one tooling rod disposed against a tool surface at a location on the tool where a composite ply is configured to overlap the tooling rod. The tooling rod may have an elongated shape and may be generally oriented along a direction of wrinkle formation in the composite ply. The tooling rod may have a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply.

Abstract: A method for forming a structural member and a structural member produced thereby includes positioning a first composite section and a second composite section within a tool. The tool has an inner surface and a wall intersection and is supported by a tool platform. The tool platform and a pressure platform are relatively movable between an open position and a closed position. The tool has a non-planar outer surface against which the member may be pressed. A composite splice member is positioned at least partially overlapping both the first composite section and the second composite section to form a joint in the composite structural member. The composite structural member is pressed against the non-planar outer surface of the tool by applying pressure to the joint from a pressure bladder. Heat is applied to the composite structural member at the joint to cure the composite splice member to the first composite section and the second composite section.

Abstract: A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.

Abstract: A heated tool assembly for forming a structural member may include a heated tool and a pressure bladder for mounting the structural member. The tool may have an inner surface, a liner in thermal contact with the inner surface of the tool, and a heating system for heating the tool. The heating system may include a heater for heating a heated medium, a blower for blowing the heated medium, and a plurality of nozzles for directing the heated medium over the tool liner.

Abstract: A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the base portion and may be formed of a plurality of substantially constant width composite plies defining a substantially constant cross-sectional shape of the keyway portion. The tip portion may be stacked on the keyway portion and may be formed of composite plies.

Abstract: A heated tool assembly for forming a structural member may include a heated tool and a pressure bladder for mounting the structural member. The tool may have an inner surface, a liner in thermal contact with the inner surface of the tool, and a heating system for heating the tool. The heating system may include a heater for heating a heated medium, a blower for blowing the heated medium, and a plurality of nozzles for directing the heated medium over the tool liner.

Abstract: A method of forming a radius filler may include providing an upper portion having substantially constant width composite plies, providing a base portion as a stack of variable width composite plies, and stacking the upper portion onto the base portion to form a radius filler stack.

Abstract: A system for diffusing wrinkles in a composite laminate may include at least one wrinkle diffuser. The wrinkle diffuser may include a diffuser body may be mounted to a tool in a manner such that a composite ply at least partially overlaps the wrinkle diffuser. A plurality of diffuser elements may be formed in the diffuser body to define a corrugated surface. The corrugated surface may cause a portion of the composite ply to assume a corrugated shape when a compaction pressure is applied to force the composite ply against the corrugated surface. The wrinkle diffuser may include an indexing feature to index the wrinkle diffuser to a ply edge of the composite ply.

Abstract: A method for forming a structural member and a structural member produced thereby includes positioning a first composite section and a second composite section within a tool. The tool has an inner surface and a wall intersection and is supported by a tool platform. The tool platform and a pressure platform are relatively movable between an open position and a closed position. The tool has a non-planar outer surface against which the member may be pressed. A composite splice member is positioned at least partially overlapping both the first composite section and the second composite section to form a joint in the composite structural member. The composite structural member is pressed against the non-planar outer surface of the tool by applying pressure to the joint from a pressure bladder. Heat is applied to the composite structural member at the joint to cure the composite splice member to the first composite section and the second composite section.

Abstract: A heated tool assembly for forming a structural member may include a heated tool and a pressure bladder for mounting the structural member. The tool may have an inner surface, a liner in thermal contact with the inner surface of the tool, and a heating system for heating the tool. The heating system may include a heater for heating a heated medium, a blower for blowing the heated medium, and a plurality of nozzles for directing the heated medium over the tool liner.

Abstract: An apparatus for forming a structural member includes a tool platform and a pressure platform that may be movable relative to one another between an open position and a closed position. The apparatus may include a tool against which the member may be pressed. The tool may be supported by the tool platform and may have an inner surface. The apparatus may include a pressure bladder configured to be pressurized for applying pressure to the member. The pressure bladder may be supported by the pressure platform for pressing the member against the tool. Also included may be a heating system for heating the tool and a tool liner in thermal contact with the inner surface for distributing heat thereto.

Abstract: An apparatus for forming a structural member includes a tool platform and a pressure platform that may be movable relative to one another between an open position and a closed position. The apparatus may include a tool against which the member may be pressed. The tool may be supported by the tool platform and may have an inner surface. The apparatus may include a pressure bladder configured to be pressurized for applying pressure to the member. The pressure bladder may be supported by the pressure platform for pressing the member against the tool. Also included may be a heating system for heating the tool and a tool liner in thermal contact with the inner surface for distributing heat thereto.

Abstract: An apparatus for forming a structural member includes a tool platform and a pressure platform that may be movable relative to one another between an open position and a closed position. The apparatus may include a tool against which the member may be pressed. The tool may be supported by the tool platform and may have an inner surface. The apparatus may include a pressure bladder configured to be pressurized for applying pressure to the member. The pressure bladder may be supported by the pressure platform for pressing the member against the tool. Also included may be a heating system for heating the tool and a tool liner in thermal contact with the inner surface for distributing heat thereto.

Abstract: A composite structural member includes first and second composite sections spliced together by an overlapping composite splice member.

Abstract: A hand assisted lamination apparatus (1) for use in making a laminated composite article, the apparatus (1) including:(a) a lay-up tool (31) for receiving plies of a composite laminating material;(b) a support table (34) for supporting the lay-up tool (31);(c) a vacuum/compressed air system for drawing a vacuum through the support table (34) and for feeding compressed air through the support table (34);(d) a laser projection system (72) for outlining the location of a ply of the composite laminating material to guide the human operator of the hand assisted lamination apparatus, the laser projection system being capable of projecting a laser beam (30) onto the lay-up tool (31) whereby the laser beam (30) traces the ply outline defined by a data set;(e) a forming/compaction bag system (35) for forming and compacting a ply of composite laminating material laid on the lay-up tool (31); and(f) an electronic control system (47) for controlling the vacuum/compressed air system, for controlling the laser projection s

Abstract: Disclosed is a machine for forming preimpregnated composite material into thin, narrow structural elements or "fillets" (18). The machine includes a cylindrical lower forming roll (26) rotatably mounted at its ends between two side plates (40). A cylindrical upper forming roll (28) is mounted above the lower forming roll and urged into frictional contact therewith. Annular protrusions (30) are formed in the periphery of the lower forming roll and project radially therefrom. Each protrusion comprises a groove (34) formed in its outermost surface that defines a die. The die, with the outer surface of the upper forming roll, combine to form an orifice (35). Each orifice is shaped substantially identical to the cross-sectional shape of the fillet. A strip of composite material (24) is fed through a series of guides and into a selected orifice. A drive mechanism (36) causes rotation of the lower forming roll and hence the frictionally contacting upper forming roll.

Abstract: In vacuum bagging and similar operations involving composite materials, it is necessary to provide both a release layer that directly contacts the composite material and will not adhere to such material, and passages for removing entrapped air. A problem with known release layers is that they are not sufficiently stretchable to provide uniform contact with complex or sharply bending surface configurations. The invention provides a breather/release material (6). Material (6) includes a flexible, stretchable foraminous fabric (10) that has a ribbed major surface (16). A foraminous coating (20) of silicone rubber release compound is formed on fabric (10) by a shrink drying process. Coating (20) conforms to the ribbed configuration of surface (16) and has holes (24) generally coinciding with holes (12) in fabric (10). Ribbed surface (16) may be bonded to an impervious layer (4) with an adhesive (8).