The Boeing Company

Andrew Lawrence Bauer

Mark E Rogalski

Geoffrey P McKnight

Jacob Michael Hundley

David W Shahan

Gwen Marie Lanphere Gross

Tiffany Allison Stewart

Christopher Paul Henry

Alexander Rubin

Brett Ian Lyons

Daniel Joseph Braley

Steven Michael Shewchuk

Troy Winfree

Eric Eldon Deck

Samuel J Tucker

Russell Patrick Mott

Trevor E Tucker

Christopher B Henry

Thomas Joseph Gonze

Nicole Renee Williams

Garrett B Peters

Carla E Reynolds

Dustin D Fast

Janet Mary Wick

David Williamson Shahan

Nicole R Williams

Janet M Wick

Thomas J Gonze

A method, apparatus, system, and computer program product for manufacturing an unconsolidated composite material. Sensor data is received from a sensor system for a composite material manufacturing system, wherein the sensor data is received during manufacturing of the unconsolidated composite material by the composite material manufacturing system. A set of predicted properties is determined for a number of portions of the unconsolidated composite material as completed from manufacturing by the composite material manufacturing system using the sensor data. A quality level for the number of portions of the unconsolidated composite material is identified based on the set of predicted properties for the number of portions of the unconsolidated composite material.

Property prediction for unconsolidated composite materials

A method of manufacturing a composite structure includes accessing design data for the composite structure that is manufactured according to a process including forming a layup of plies of fibers using a machine tool. The method includes applying the design data to an ANN classifier to classify a localized inconsistency of a type of inconsistency on the composite structure, the localized inconsistency spatially referenced to a location on the composite structure. The method includes performing a root cause analysis to identify one or more of process parameters as a potential cause of the type of inconsistency, and modifying one or more of the geometric model, the layup design, or values of the one or more of the process parameters to address the potential cause.

Composite manufacturing using data analytics

A system, apparatus, computer program product, and a method for manufacturing an unconsolidated composite material. Sensor data is received from a sensor system for a composite material manufacturing system. The sensor data is received during manufacturing an unconsolidated composite material by the composite material manufacturing system. A set of predicted properties is determined for a number of portions of the unconsolidated composite material using the sensor data. The set of predicted properties is for the number of portions of the unconsolidated composite material as a completed product. A corrective action is performed based on a quality level for the number of portions of the unconsolidated composite material.

System and method for material manufacturing based on predicted properties of unconsolidated composite material

Methods and apparatus to increase fire resistance and fracture toughness of composite structures are described. An example multi-ply composite structure has at least eleven plies including an innermost ply forming a first external surface of the multi-ply composite structure, and an outermost ply forming a second external surface of the multi-ply composite structure, with the second external surface being located opposite the first external surface. The at least eleven plies further include at least one and no more than three fire-resistant plies positioned between the innermost ply and the outermost ply within either an innermost 33% of the at least eleven plies or an outermost 33% of the at least eleven plies. Respective ones of the fire-resistant plies include an epoxy-based resin and a first additive mixed into the epoxy-based resin. The first additive increases a flammability resistance of the multi-ply composite structure.

Methods and apparatus to increase fire resistance and fracture toughness of a composite structure

Methods and apparatus to increase fire resistance and fracture toughness of a composite structure are described. An example apparatus includes a composite structure formed by an innermost ply and a fire-resistant ply including a first additive to increase a flammability resistance of the structure, where the fire-resistant ply is an inner ply of the composite structure.

Core structures () for composite panels () of an aircraft (), composite panels () and aircraft () including the core structures (), and methods () of manufacturing the composite panels () are disclosed herein. The core structures () include a first side (), a second side (), and a connecting region () that interconnects an upper portion () of the first side () with an upper portion () of the second side (). The first side (), the second side (), and the connecting region () at least partially define an antenna housing (), which defines a housing volume () configured to contain an aircraft antenna () of the aircraft (), and an electromagnetic wave transmission region () configured to permit electromagnetic waves to pass therethrough. The electromagnetic wave transmission region () defines a plurality of kite-shaped voids () arranged in a repeating pattern and bounded by a corresponding plurality of walls (), at least 10% of which extends at least substantially perpendicular to a surface () that bounds the electromagnetic wave transmission region ().

Core structures for composite panels of an aircraft, composite panels and aircraft including the core structures, and methods of manufacturing the composite panels

Growing community of inventors

Kirkland, WA, United States of America

Andrew Lawrence Bauer