The Boeing Company

Scott Edward Krajca

Darrell Darwin Jones

Kurtis Shuldberg Willden

Long H Ly

Chace Wilcoxson

William Thomas Kline

Daniel R Smith

Jeremy Evan Justice

Nicholas Boroughs

Thomas Dean Wilson

Bruno Zbinden

Dalton C Bergan

Gregory R Klempel

Joseph Fount Warren, Jr

Michael A Lee

Joseph Warren

Lisa Christina Carlson

Erik Lund

Gabriel Zane Forston

Paul Chace Wilcoxson

Mark S Bunker

Michael Karas

Josiah Brubaker

Christopher Gary Harris

Joseph L Sweetin

Garrett C Hanson

Jonathan Y Ahn

Silas Lawton Studley

James P Dobberfuhl

Steven Kuan-chi Wu

Matt Christner

Elise Rae Ermitano Castorina

Austin T McAnelly

Marko Oviir

Joel Crain

Jacob E Koopmans

Marcus C Hart

Deborah A Fisher

Daniel Smith

Wade Morris

Cooper A Wessells

Keegan Chamberlain

Justin K Alfred

Hiteshkumar M Patel

Carlos Walker

Paul Lesovoy

Pavel Lesovoy

Steven Kuan-Chi Wu

Daniel R Smith Jr

Long Hoang Ly

Austin T Mcanelly

Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.

Fabrication of multi-segment spars

A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.

Forming apparatus, method, and system

The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.

Systems and methods for forming composite members

There is provided an automated removal apparatus for selectively removing one or more trimmed portions of a laminated ply in a ply-by-ply fabrication process. The automated removal apparatus includes a rotatable reel having a plurality of retractable vacuum panels attached around the rotatable reel. Each retractable vacuum panel has one or more retractable vacuum pad assemblies, and each retractable vacuum pad assembly has a vacuum pad with a vacuum port and a self-sealing valve. The automated removal apparatus further includes actuator assemblies attached to the plurality of retractable vacuum panels, friction reducing elements attached around the rotatable reel, a drive assembly attached to the rotatable reel, and a pneumatic system attached to the rotatable reel and including a valve manifold operable to control an air flow to the actuator assemblies and to one or more vacuum generators to generate a vacuum flow.

Automated removal apparatus, system, and method for selectively removing trimmed portions of a laminated ply in a ply-by-ply fabrication process

A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.

Multi-lane tows for use with ply-by-ply forming machines

A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.

System and method for fabricating a composite structure

A system for placing a composite ply includes a transfer end effector that is movable relative to a carrier transfer device, configured to convey a ply carrier that supports the composite ply, and a placement end effector that is movable relative to the transfer end effector and to a forming tool. The transfer end effector is configured to remove the ply carrier, supporting the composite ply, from the carrier transfer device and to position the ply carrier for removal by the placement end effector. The placement end effector is configured to remove the ply carrier from the transfer end effector and to apply the composite ply to the forming tool.

Composite ply placement system and method

Provided is an automated method for trimming a multi-ply structure having at least a first ply and a second ply, where the method includes applying the first ply over a platen, positioning a cutting board over a protected portion of the first ply, applying the second ply over the platen such that the cutting board is between the protected portion of the first ply and a superjacent portion of the second ply, and cutting the superjacent portion of the second ply.

Automated method and system for trimming a multi-ply structure

Systems and methods according to one or more embodiments are provided for a flexible and local laser shroud that conforms to a contoured work surface and confines laser light energy from a laser end effector to the work surface. In one example, a system includes a laser end effector coupled to a robotic arm to provide laser light energy to a work surface. The system also includes a shroud coupled to the end of the robotic arm and extending to the work surface. The system further includes, as part of the shroud, a flexible laser light seal to conform to the work surface to substantially prevent the laser light energy from passing between the shroud and the work surface as the laser end effector travels along the work surface.

Flexible and local laser shroud

Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.

Systems and methods for forming radius fillers for composite structures

Methods for forming radius fillers for composite structures are disclosed herein. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.

Methods for forming radius fillers for composite structures

Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a first support surface and a support surface edge. The systems further include a second support surface, a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include supporting the second portion of the sheet with a second support surface and separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface.

A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the base portion and may be formed of a plurality of substantially constant width composite plies defining a substantially constant cross-sectional shape of the keyway portion. The tip portion may be stacked on the keyway portion and may be formed of composite plies.

Variable-radius laminated radius filler and system and method for manufacturing same

Growing community of inventors

Seattle, WA, United States of America

Scott Edward Krajca