Spirit Aerosystems, Inc.

Blaise Francis Bergmann

Darin Clay Wiley

Aaron Rae Heitmann

James Edward Westerman

Christopher John Morrow

Michael C Dowling

John Patrick McPherson

Benjamin Wayne Ferrell

Brian Charles Clapp

Christopher James Padovano

Allison Lynne Horner

Roger Edmund Kornfeld

Michael Arthur Champa

Michael J Stuckey

Walter A Chappelle

Joseph Lynn Michelucci

Mark S Williams

Scott Sellmeyer

Dwight D Spaulding

Johnathan Scott Klincik

Tobias DiGennaro

A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.

Method of seamlessly bagging composite parts

An apparatus for picking, placing, and forming a composite charge over a complex geometry tool comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed from rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed from flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and located along the perimeters of the first frame and the second frame. Each dynamic mechanism includes a length-variable component positioned between the first frame and the second frame, with at least a portion of the dynamic mechanisms configured to vary a length of the length-variable component for the second frame member to conform to the shape of the complex geometry tool.

Integrated pick, place and forming apparatus and method for composite charges over complex geometries

A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.

Composite aerodynamic structure

Integrated pick, place, and forming apparatus and method for composite charges over complex geometries

A system and method for fabricating large composite fuselages or other vehicle structures, in which the composite structure is fabricated and cured as on a tool, segmented and removed from the tool without disassembling the tool, and then reassembled off the tool to reform the large structure. The tool includes mandrel segments attached to a substructure. The attachments may be moveable to accommodate differential expansion and contraction during curing, and the tool may be rotatable to facilitate access. A composite material of resin and synthetic fibers is applied over the mandrel segments to fabricate the structure on the tool. Caul plates are secured over the composite material, and the composite material is cured on the tool. The resulting structure is cut into part segments which are then removed from the tool, and the part segments are joined to reassemble the large composite structure off the tool.

System and method for fabricating and curing large composite structures

A system and method for splicing multiple plies of material together during the construction of a stringer sheet. A first ply layer is laid onto a portion of a surface of a tool having a contour which defines a stringer, and the first ply layer is pressed down such that an edge of the first ply layer is located on the contour. A second ply layer is laid onto an adjacent portion of the surface, and the second ply layer is pressed down such that the edge of the second ply layer is located on the contour and overlaps the edge of the first ply layer. This process may be repeated for additional ply layers. The system may include an end-effector having a dispenser of the plies of material and a roller for pressing the plies, and a movement mechanism for moving the end-effector over the tool.

System and method for splicing plies in stringer sheets

An aircraft panel assembly including a panel, a number of open-ended composite stringers, and a number of stringer end caps. Each stringer end cap covers an open end of one of the stringers and includes a base, a vertically extending wall, and an overlap section. The base is bonded to the panel near the open end of the stringer. The vertically extending wall is angled upward from the base and includes an upper periphery. The overlap section extends horizontally from the upper periphery and is bonded to the stringer near the open end of the stringer.

Composite stringer end cap

A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Method and bladder apparatus for forming composite parts

A cure tool assembly and method of manufacturing a composite part. The cure tool assembly may include a rigid cure tool having a cutter groove and a securing groove formed therein. The cutter groove may be spaced apart from and formed around the cutter groove. The securing groove may be slanted inward, away from a peripheral edge of the rigid cure tool. The cure tool assembly may also include a first sacrificial material located in the cutter groove and a second sacrificial material located in the securing groove. Composite material placed onto the outer surface of the rigid cure tool may bond with the second sacrificial material during cure, creating a desired hold-down force to keep the composite material in place. The resulting cured part may be cut along the cutter groove, thus cutting through the composite material and into the first sacrificial material.

Secondary groove for work piece retention during machining

A manufacturing method is adapted for materials that are susceptible to deformation during the manufacturing process, such as composite parts that change shape during curing. The method includes modifying a part design to compensate for changes in the shape of the part that occur during a curing phase of the manufacturing process. A manufacturing mold is created according to the modified part design, then a part is formed in the mold and cured in the mold. While the part is still in the mold after the curing phase, the part is finished according to the modified part design wherein excess material is removed and apertures are created. While the part is still in the mold after the finishing phase, the finished part is inspected using automated inspection equipment to confirm that the finished part conforms to the modified part design.

Methods and systems for dimensional inspection of compensated hardware

A system for forming composite material parts comprises a charge station, a tool station, a forming station, a cooling station, a pick and place apparatus, and a transfer unit. The charge station may receive a first charge. The tool station may receive a first tool. The forming station may form a second charge against a second tool. The cooling station may cool a third charge and a third tool. The pick and place apparatus may retrieve the first charge from the charge station and the first tool from the tool station and transport both the first charge and the first tool to the forming station. The transfer unit may transport the second charge and the second tool from the forming station to the cooling station while at the same time transporting the third charge and the third tool from the cooling station to the tool station.

Automated multi-stage machine for forming composite details

A translating die apparatus and method for forming a piece of material into a part having complex contours. The translating die apparatus may comprise upper and lower mounts, fixed upper and lower dies fixed to the upper and lower mounts, respectively, and movable upper and lower dies translatably coupled with the mounts and configured to translate laterally toward and away from the fixed upper and lower dies. The piece of material may be placed between the upper and lower dies and one of the mounts may be actuated toward another of the mounts to sandwich the piece of material between the upper and lower dies. Simultaneously, the movable upper and lower dies may translate toward the fixed upper and lower dies, until the movable and fixed dies abut each other when the upper and lower dies are fully pressing the piece of material therebetween.

Translating forming dies

A method and part forming apparatus configured for forming an aircraft stringer. The part forming apparatus may comprise a forming tool, a rigid plate, and a hollow bladder. The forming tool may comprise a material trough, a bladder extension trough laterally aligned with and open to the material trough, and a recessed pocket extending from either side of the bladder extension trough and adjacent to the material trough. The method comprises placing composite material into the material trough, placing the bladder onto the composite material and through the bladder extension trough, placing the rigid plate into the recessed pocket and over the bladder, and then placing skin laminate over the bladder and the composite material. Once each of these components is in place, the forming tool may be vacuum bagged and the composite material and skin laminate may be co-cured to form the stringer.

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Clearwater, KS, United States of America

Blaise Francis Bergmann