The Boeing Company

University of Washington

Nathan Alphonse Secinaro

Samuel Francis Pedigo

Silas Lawton Studley

Shuonan Dong

Santosh Devasia

Lucky Singh

Devin Ide

Connor Burch

Nini Hong

James Hutchinson

Lukas Wavrin

Kevin Hsu

Theodore J Sergesketter

Brent F Craig

Michael Chih-Huan Wang

Hsien-Lin Huang

Mark Abdouch

Douglas Alan Jones

Benjamin Samuel Merrit

Daniel Bracy

A method of manufacturing a backed cross-ply prepreg comprises cutting, using a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The method also includes picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The method also includes feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine, and adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing material.

System and method for manufacturing cross-ply pre-impregnated material

A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.

A method of manufacturing a panel assembly includes supporting the panel assembly in a free state using a holding fixture. The panel assembly has a skin panel, and sacrificial material coupled to a skin panel inner surface. The method includes acquiring a free state outer surface contour of the panel assembly by scanning a skin panel outer surface while the panel assembly is supported by the holding fixture. The method also includes developing a numerically controlled (NC) machining program having cutter paths configured for machining the interface locations to an inner surface contour that reflects nominal thicknesses of the panel assembly based off of the free state outer surface contour. In addition, the method includes machining the sacrificial material at the interface locations by moving a cutter along the cutter paths while the panel assembly is supported by the holding fixture.

Method of manufacturing an assembly having a nominal thickness skin panel

A method for three-dimensional (3D) inspection of a workpiece for conformance to a specification includes scanning, by a 3D optical scanning device, a hole formed in a workpiece to generate a 3D point cloud of the hole defined in a 3-axis coordinate system of the 3D optical scanning device. The 3D point cloud includes 3D point cloud data that provides a profile of the hole. The method also includes translating the 3D point cloud data to generate translated 3D point cloud data that facilitates analysis of the 3D point cloud. The method further includes performing analysis of the hole using the translated 3D point cloud data to determine conformance of the hole with a specification and to detect anomalies associated with the hole.

Three-dimensional inspection of a workpiece for conformance to a specification

A system for passive deployment of a vortex generator is disclosed, including a housing mounted at a fixed location relative to an airfoil structure and a piston contained in the housing. A vortex generator is moveably mounted adjacent an exterior surface of the airfoil structure, and is moveable between a stowed position inside the airfoil structure and a deployed position outside the airfoil structure. The piston is configured to drive the vortex generator between the stowed position and the deployed position in response to a pressure differential between a first airstream over a first surface of the airfoil structure and a second airstream over a second surface of the airfoil structure.

Vortex generator passive deployment system

A method of manufacturing a shim and related systems and equipment. A mechanical tool inserted into a shim space defined between two or more components with the mechanical tool in a first configuration. The mechanical tool is free of measurement electronics. The mechanical tool, while in the shim space, is modified such that the mechanical tool assumes a second configuration to establish a plurality of model points corresponding to a boundary surface of the shim space. The mechanical tool is removed from the shim space while maintaining the mechanical tool in the second configuration. Using a measurement station distinct from the tool, the positions of the model points are electronically measured while the mechanical tool is both disposed outside of the shim space and in the second configuration. Machining instructions are generated based on the measured positions. A shim is fabricated based on the generated machining instructions.

Shim manufacturing methods and devices

An actuation mechanism, a flap mechanism, and an aircraft. The actuation mechanism includes drive links and drive mechanisms connected to opposite ends of the flap that move the flap to various positions. The drive mechanisms are actuated by torque tubes connected to a drive motor via a differential. The differential distributes torque to the torque tubes. In the event of abnormal operation of one of the drive links or drive mechanisms, the differential limits torque to the remaining drive link and drive mechanism such that the flap does not deploy or retract in a skewed manner.

Differential for control surface actuators

Growing community of inventors

Seattle, WA, United States of America

Nathan Alphonse Secinaro