The Boeing Company

Dwight L Engwall

Christopher John Morrow

Randall R Clark

Kevin J Steen

Jeffrey A New

Roger A Johnson

Chris J Morrow

Mark G Yonash

Mark Andrew Schmier, Ii

Carlos Pena

Gary Eugene Jones

Jonathan Christopher Heath

Frederick C Edman

Basilio Penuelas

John Michael Costello

Stephen Doyle

Richard R Fengler

Thomas G Klingler

Peter K Bilitsis

Richard D Tuzzolino

Erwin R Kuhn

Lawrence M Apodaca

Configurable layup tooling used to fabricate reinforced composite parts having a common shape but varying features are disclosed herein. An example apparatus disclosed herein includes a common tool body. A first mandrel is received by the common tool body to form at least a first portion of a common shape and a first profile of a first part to be formed via the common tool body. A second mandrel is received by the common tool body to form the first portion of the common shape and a second profile of a second part that is different from the first part.

Configurable tooling and molding method using the same

Configurable layup tooling is used to fabricate reinforced composite parts have a common shape but varying features. The tooling includes a tool base, multiple mandrels and optionally, a tool insert, all of which may be used to form a portion of the common shape. The mandrels have differing tool geometries for forming the varying features of the commonly shaped parts. The tool base may be used as a bonding jig to assemble and bond assemblies that include the fabricated parts.

A method for fabricating stringers is provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Method for fabricating stringers

A mobile storage and work cart is described that includes a reconfigurable frame, a plurality of casters extending from the reconfigurable frame and operable for moving the cart, and a work surface attached to the reconfigurable frame and forming a top of the cart. The reconfigurable frame is operable to adjust a height of the work surface.

Multiple use, transformable cart

Embodiments of an assembly for securing a stringer to a substrate are provided. The stringer assembly includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Assembly for securing a stringer to a substrate

An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. Multiple composite material delivery heads simultaneously deliver material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery heads inside the interior mandrel surface. A connecting mechanism connects the material delivery heads to the gantry beam and provides motion of the material delivery heads relative to the interior mandrel surface.

Unidirectional, multi-head fiber placement

A co-cured composite stringer and associated apparatus and method are provided. The co-cured composite stringer includes a stringer and a mandrel positioned within a channel defined in the stringer. A plurality of strips are positioned within an opening of the mandrel, and a substrate layer, such as aircraft skin, is positioned adjacent to the stringer. During application of the substrate layer to the stringer, the mandrel and plurality of strips support the stringer.

Co-cured stringers and associated mandrel and fabrication method

The present invention provides a method and apparatus for use in manufacturing a composite part includes molding a composite part on a lay-up tool, machining a sacrificial portion of a first surface for securing a first hardware device with the composite part while the part is on the lay-up tool and cutting the part forming a peripheral edge while the part is on the lay-up tool. The method can further include positioning the first hardware device in contact with a machined interface of the composite part and machining the part including drilling a plurality of positioning holes through the hardware device and the part while the part is on the lay-up tool. The machining can include machining the sacrificial portion creating a machined interface and positioning the hardware device on the machined interface.

Triple purpose lay-up tool

An aircraft part manufacturing device for automated composite lay up includes a mandrel tool having a an interior mandrel surface that conforms to an outside mold line (OML) of a part: to be manufactured. One or more circular rings surround the mandrel and are attached to the mandrel. The circular rings rotate supported by bearings in a bearing cradle so that the mandrel rotates concentrically with the circular rings about an axis of rotation passing through the center of the circular rings. A composite material delivery head delivers material directly to the outside mold line on the interior mandrel surface while the mandrel is rotated. A cantilever supported gantry beam supports the material delivery head inside the interior mandrel surface. A connecting mechanism connects the material delivery head to the gantry beam and provides motion of the material delivery head relative to the interior mandrel surface.

Automated composite lay-up to an internal fuselage mandrel

A method of manufacturing a composite uses a hybrid tool which serves both as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration, and as a fixture for holding the bonded or cured materials in the originally applied position during subsequent machining of a peripheral edge of the part. The method includes fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The materials for the part are applied on the face sheet, debulked, bonded or cured, and edge trimmed thereon, all while on the face sheet in the originally applied position.

Method for making a composite

A hybrid tool serves as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration. It also serves as a holder for the bonded or cured materials in the originally applied position during subsequent machining. The hybrid tool is made by fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The actual part will be laid up on the facing surface, cured while on the tool, and even trimmed before release. Base structure of the tool holds the facing surface of the face sheet in the desired shape, and includes ground-engaging pads that define an &ldquo;A&rdquo; datum plane. The tool aligns a reference plane of the face sheet parallel to the datum plane. A substantially continuous groove in the face sheet, used for trimming the part, opens in the facing surface. Edge trimming of the part on the tool is performed using a CNC machine tool following a part program to move a cutter extending into the groove to engage the full thickness of the part. The groove corresponds in space to the position represented by the cutter path of travel in the part program because of the accurate spatial relationship of the face sheet reference plane and the datum plane. One embodiment of the invention includes filling the groove in the facing surface with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, which fills the groove and forms a hard, smooth surface skin, flush with the facing surface of the tool to support the part during lay up. A series of skin plies are laid-up to form a tool-side skin, and other components of the part are laid-up on the tool-side skin. A vacuum bag is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components. An adhesive/resin matrix in the skin and components is bonded/cured in the conventional manner within the vacuum bag to produce a rigid integral assembly. The vacuum bag is removed, uncovering the rigid integral assembly for trimming. A cutter of a machine tool is guided on a predetermined path around the facing surface of the tool, running in the foam-filled groove below the facing surface of the tool and cutting a peripheral edge around the rigid integral assembly. After trimming, the rigid integral assembly is removed from the facing surface of the tool.

Hybrid lay-up tool

A hybrid tool serves as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration. It also serves as a holder for the bonded or cured materials in the originally applied position during subsequent machining. The hybrid tool is made by fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The actual part will be laid up on the facing surface, cured while on the tool, and even trimmed before release. Base structure of the tool holds the facing surface of the face sheet in the desired shape, and includes ground-engaging pads that define an 'A' datum plane. The tool aligns a reference plane of the face sheet parallel to the datum plane. A substantially continuous groove in the face sheet, used for trimming the part, opens in the facing surface. Edge trimming of the part on the tool is performed using a CNC machine tool following a part program to move a cutter extending into the groove to engage the full thickness of the part. The groove corresponds in space to the position represented by the cutter path of travel in the part program because of the accurate spatial relationship of the face sheet reference plane and the datum plane. One embodiment of the invention includes filling the groove in the facing surface with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, which fills the groove and forms a hard, smooth surface skin, flush with the facing surface of the tool to support the part during lay up. A series of skin plies are laid-up to form a tool-side skin, and other components of the part are laid-up on the tool-side skin. A vacuum bag is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components. An adhesive/resin matrix in the skin and components is bonded/cured in the conventional manner within the vacuum bag to produce a rigid integral assembly. The vacuum bag is removed, uncovering the rigid integral assembly for trimming. A cutter of a machine tool is guided on a predetermined path around the facing surface of the tool, running in the foam-filled groove below the facing surface of the tool and cutting a peripheral edge around the rigid integral assembly. After trimming, the rigid integral assembly is removed from the facing surface of the tool.

A method of manufacturing a laid-up, bonded and, cured composite part, includes filling a groove on a facing surface of a tool with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, filling the groove and forming a hard, smooth surface skin on the foam, flush with the facing surface of the tool. A series of plies are laid-up on the facing surface of the tool to form a tool-side skin, and other components of the part are laid-up on top of the tool-side skin plies. An adhesive/resin matrix is coated on or pre-impregnated into the skin plies and the components for bonding/curing to create a rigid integral assembly of the skin and components. A vacuum bag is applied over the laid-up skin and components and is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components. Air is evacuated from under the vacuum bag to cause air pressure outside the vacuum bag to press the vacuum bag against the components. The adhesive/resin matrix is bonded/cured to transform the skin and components into the rigid integral assembly. The vacuum bag is removed from the facing surface of the tool, uncovering the rigid integral assembly. The tool is fixed in a known position on a CNC machine tool bed to position the facing surface of the tool at a known position for edge routing of the rigid integral assembly by a machine tool. A cutter of the machine tool is guided on a predetermined path around the facing surface of the tool, with the cutter extending into the groove below the facing surface of the tool and cutting a peripheral edge around the rigid integral assembly. After edge routing, the rigid integral assembly is a finished part and is removed from the from the facing surface of the tool.

Dual purpose lay-up tool

A reconfiguration table, for holding and supporting a contoured workpiece while work is performed thereon comprising a frame defining a perimeter and a plane; a plurality of support elements disposed in spaced array within the frame perimeter, each element having an end and being independently translatable in a direction substantially perpendicular to the plane, the ends of the elements cooperating to define a support surface for the workpiece; clamp members, supported by the frame, for selectively locking the elements in position to define the support surface; attaching members, supported by the frame independently of the support elements, for holding the workpiece on the support surface; and a gear reducer and motor for rotating the frame with the workpiece supported thereon about an axis parallel to the plane of the frame.

Growing community of inventors

Haysville, KS, United States of America

Dwight L Engwall