Abstract: A roller device for use in an automated fiber placement process for creating composite parts on a contoured tool. A helical spring provides a bendable axle, and a roller cover fits over the spring axle. A tension mechanism is arranged through the spring axle along a centerline axis, and is adjustable to control a bendability of the spring axle so as to more closely conform to particular contours of the tool. The tension mechanism may include a cable extending through the spring axle, a threaded portion at an end of the cable, and a screw received within the threaded portion and turnable to adjust a length of the tension mechanism and thereby adjust the bendability of the spring axle. The tension mechanism may be adjustable manually, semi-manually with a motor controlled by a user, or automatically with a motor controlled by an electronic controller.

Abstract: A roller device for use in an automated fiber placement process for creating composite parts on a contoured tool. A helical spring provides a bendable axle, and a roller cover fits over the spring axle. A tension mechanism is arranged through the spring axle along a centerline axis, and is adjustable to control a bendability of the spring axle so as to more closely conform to particular contours of the tool. The tension mechanism may include a cable extending through the spring axle, a threaded portion at an end of the cable, and a screw received within the threaded portion and turnable to adjust a length of the tension mechanism and thereby adjust the bendability of the spring axle. The tension mechanism may be adjustable manually, semi-manually with a motor controlled by a user, or automatically with a motor controlled by an electronic controller.

Abstract: A system and method of vacuum assisted resin transfer molding (VARTM) using a reconfigurable material, such as shape memory polymer (SMP), for a caul sheet or a forming tool. The reconfigurable material may have a rough or non-smooth, deformed configuration to serve as a flow media during resin transfer, but may be triggered to return to a smooth memory shape at composite cure temperatures at least high enough to place the reconfigurable material into a malleable state. Thus, a surface of the composite material facing the reconfigurable material will have a substantially smooth finish following curing thereof. The rough or non-smooth deformed configuration may be created by embossing or otherwise forming various patterns into the reconfigurable material in the malleable state, and holding this pattern while triggering the reconfigurable material back to a rigid state for use during resin transfer.

Abstract: A sealing device for forming an airtight seal between a first body, such as a cure tool, and a second body, such as a vacuum bag, without the use of adhesives. The sealing device may comprise an outer surface attached to the second body, an inner surface configured to face the first body, and two cusps located at opposite edges of the inner and outer surfaces. The sealing device may form a continuous boundary around an area of any shape or size. The sealing device may have a substantially crescent-shaped cross-section, allowing the sealing device to suction to the first body when compressed against the first body. The sealing device may also comprise a tab portion protruding from the inner surface between the first and second cusp for providing a more secure seal between the sealing device and the first body.

Abstract: A reusable apparatus and method for forming a composite part through vacuum assisted resin transfer molding (VARTM). The reusable apparatus may be configured to vacuum seal a curable material, such as composite material, against a tool and disperse a permeating substance such as liquid resin through the curable material. The reusable apparatus may comprise a sheet of material such as rubber having a plurality of surface deviations facing the curable material and the tool. The surface deviations may provide paths for evenly distributed air flow as air is evacuated from between the sheet of material and the tool. Additionally, the surface deviations may allow the permeating substance to be evenly dispersed throughout the curable material. A vacuum outlet of the tool may be positioned between two sealing apparatuses to provide continuous vacuum suction proximate a perimeter of the sheet of material to prevent air from leaking in.

Abstract: A sealing device for forming an airtight seal between a first body, such as a cure tool, and a second body, such as a vacuum bag, without the use of adhesives. The sealing device may comprise an outer surface attached to the second body, an inner surface configured to face the first body, and two cusps located at opposite edges of the inner and outer surfaces. The sealing device may form a continuous boundary around an area of any shape or size. The sealing device may have a substantially crescent-shaped cross-section, allowing the sealing device to suction to the first body when compressed against the first body. The sealing device may also comprise a tab portion protruding from the inner surface between the first and second cusp for providing a more secure seal between the sealing device and the first body.

Abstract: A reusable apparatus and method for forming a composite part through vacuum assisted resin transfer molding (VARTM). The reusable apparatus may be configured to vacuum seal a curable material, such as composite material, against a tool and disperse a permeating substance such as liquid resin through the curable material. The reusable apparatus may comprise a sheet of material such as rubber having a plurality of surface deviations facing the curable material and the tool. The surface deviations may provide paths for evenly distributed air flow as air is evacuated from between the sheet of material and the tool. Additionally, the surface deviations may allow the permeating substance to be evenly dispersed throughout the curable material. A vacuum outlet of the tool may be positioned between two sealing apparatuses to provide continuous vacuum suction proximate a perimeter of the sheet of material to prevent air from leaking in.

Abstract: A reusable vacuum bag apparatus for use in a compaction operation by which composite parts are formed. The apparatus includes a flexible, inflatable support structure which is secured to a reusable flexible mat vacuum bag. When inflated, the support structure maintains the vacuum bag in the orientation it needs to assume when placed on a forming tool associated with a compaction apparatus. The support structure is formed by a plurality of intercoupled linear and curving tubing segments which form a grid-like support structure. The support structure is shaped in accordance with the configuration and contours of the reusable vacuum bag portion, which is in turn shaped in accordance with a forming tool. The support structure can be de-inflated, which allows the vacuum bag secured thereto to be stored in a compact arrangement when not in use.