Northrop Grumman Systems Corporation

Alliant Techsystems Inc.

General Electric Company

Orbital Atk, Inc.

Northrop Grumman Innovation Systems, Inc.

Christopher James Madsen

John B Healey

Vernon M Benson

Todd A Rosevear

Eric McNabb

Ralph Douglas Cope

Jason K Slack

Steven Andrew Cope

Anthony Dale Johnson

Peter G Turner

Michael James Case

Kimberly Ann Ferrara

Kyle Putnam Tarry

Don C Jones

Jesse Paul Brown

James Gargel

Stefaan Guido Van Nieuwenhove

Mathias Ernst Messmer

Martin Petersen

Thomas Kluge

Wayne M Roeber

Travis S Olsen

Ethan J Hoffman

Jason H Stulp

Michael T Tueller

John Schowengerdt

Kevin Fehlmann

Sultan Shair

Ram Kumar Upadhyay

Boyd L Hatch

Andreas Lutz

Matthew Hall Beaumont

Kyle E Chapman

Kimberley Ann Ferrara

Todd Rosevear

Methods of forming a composite structure include conforming at least one ply of material to a forming surface of a tool having differing features. Apparatuses for forming a composite structure include a forming tool and a material feed assembly configured to hold a supply of material, where the material feed assembly may be configured to pivot the supply of material relative to the forming tool. Composite structures having an at least partially annular shape are formed by an at least partially automated process.

Composite structures, forming apparatuses and related systems and methods

Material preparation devices and related methods include a material or substrate assembly and an application assembly for applying a fiber material.

Material preparation device and related methods

A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

Radially extending composite structures

A method and an automatic layup system for making a stack of a plurality of composite plies are presented. The automatic layup system includes a stacking assembly located in a first plane and a layup tool located in a second plane parallel to the first plane. The stacking assembly and the layup tool are movable towards each other. The method includes the steps of (a) providing one or more composite sheets between the layup tool and the stacking assembly, (b) generating a first composite ply from the one or more composite sheets, (c) placing the first composite ply on the layup tool by the stacking assembly by bringing the stacking assembly and the layup tool close to each other, and (d) repeating the steps (b) and (c) for generating and placing a second composite ply on the first composite ply, which is placed on the layup tool.

Automatic systems and methods for stacking composite plies

An automated in-line feed-through system and method, integrates the ability to control one or more variables during part fabrication with the layup of one or more fiber tows to form a composite part. The system includes an automated layup system configured to receive a feed-through of one or more fiber tows as an input material. The automated in-line feed-through system further includes a controller configured to respond to measurement data obtained by one or more samplings of the input material and/or a plurality of laid up plies that form a laminate. The controller in response to the obtained measurement data provides adjustment of the feed-through of the one or more fiber tows to compensate for a variation in one or more of the weights from a reference weight.

System and method for controlling at least one variable during layup of a composite part using automated fiber placement

A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber-reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second, different orientation relative to an edge of the formed bias-ply.

Material preparation device

A material preparation device is provided. The material preparation device includes a bias-ply assembly, a feedstock assembly and an application head. The bias-ply assembly is configured to pass a bias-ply backing material along a first path. The feedstock assembly is configured to pass a feedstock along a second path that crosses the first path at a select angle. The feedstock includes resin pre-impregnated fiber reinforced material (pre-preg) having the fibers at a first orientation relative to an edge of the feedstock. The application head is configured to transfer the pre-preg from the feedstock to the bias-ply backing material at a location where the first path crosses the second path to form a bias-ply with the fibers of the pre-preg having a second different orientation relative to an edge of the formed bias-ply.

Automated bias-ply preparation device and process

An automated material delivery system including a material handling assembly, a compaction member, a handling actuator, and a cutting actuator is provided. The material handling assembly is configured and arranged to guide material. The material handling assembly includes a tacking member that is configured and arranged to selectively press the material over a forming surface of a tool. The compaction member is spaced a select distance from the tacking member. The compaction member is further configured to selectively press the material over at least a portion of the forming surface of the tool. The handling actuator is coupled to selectively move at least one of the material handling assembly and the compaction member to move the material handling assembly in relation to the compaction member. The cutting assembly is positioned between the tacking member and the compaction member. The cutting assembly is configured and arranged to selectively cut the material.

Automated material delivery system

Method and apparatus for forming an annular composite structure is provided. In one embodiment an apparatus for forming annular composite structures is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool.

Automated composite annular structure forming

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Ogden, UT, United States of America

Christopher James Madsen