The Boeing Company

Theboeing Company

University of Washington

Silas Lawton Studley

James Niemann Buttrick

Darrell Darwin Jones

Matthew Ray DesJardien

Samuel Francis Pedigo

Lisa Christina Carlson

Garrett C Hanson

Shuonan Dong

Nathan Alphonse Secinaro

Glenn R Dalby

Santosh Devasia

Lucky Singh

Richard W Baird

Devin Ide

Kevin Hsu

Lukas Wavrin

James Hutchinson

Nini Hong

Connor Burch

Kurtis Shuldberg Willden

Daniel R Smith

Brian Gregory Robins

Shane Edward Arthur

Brad Andrew Coxon

John Dempsey Morris

John Eric Miller

Matthew H Mellin

Scott Edward Krajca

Jonathan Y Ahn

Erik Lund

Bennett M Moriarty

Bruce S Howard

Gagandeep Saini

Raymond C Eng

Terrence J Rowe

Paul Chace Wilcoxson

Mark C Boberg

Kyle Steven Biondich

Jake Adam Reeves

Long H Ly

Chace Wilcoxson

Steven J Plummer

Mark S Bunker

Robert William Whiting

Daniel Mark McDonagh

Davis Tran

Matthew R Desjardien

Derek J Flolid

Stephen Glade Holley

Dhananjay B Vasa

Benjamin Bowen Lee

Michael Karas

Tracy Edward Zimmerman

Daniel Saeil Martin

Derek Willis

Gregory P Freed

Eric J Walker

John D O'Connell

Blake Rafferty

Steven Joseph Plummer

Darell Darwin Jones

Jonathan Young Ahn

John D O'CONNELL

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

Composite laminate stiffeners such as stringers are punch formed between first and second universal dies respectively carried on first and second trays. The second tray is mounted for sliding movement relative to the first tray between a punch position and a compaction position. Parts of the first and second dies are easily reconfigurable, allowing different shapes of stiffeners to be formed on the same forming apparatus.

Stringer forming apparatus and method

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 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

An ergonomic frame-filler placement tool is manually operable to supply a vacuum fluid flow at a distal end of the tool that can be used by a worker to pick up and hold a piece of frame-filler material to the distal end of the tool, which enables the worker to manipulate the tool to position the piece of frame-filler material over a desired location of a fuselage mandrel and then manually stop the vacuum fluid flow at the distal end of the tool to position the piece of frame-filler material at the desired location on the mandrel.

Ergonomic frame-filler placement tool for manual installation

A system and method for forming a composite part. The method comprises positioning a prepreg material relative to a composite forming tool. The composite forming tool comprises a frame associated with a shaping system, a base comprising at least one mold, and the shaping system associated with the frame and configured to move relative to the frame, the base, and the prepreg material. The method also lowers the shaping system of the composite forming tool towards the prepreg material. The method applies pressure to the prepreg material with a centerline presser of the shaping system. The method also applies a force to the prepreg material using a number of compliant elongate members of the shaping system to uniformly apply the prepreg material to the at least one mold of the base of the composite forming tool.

Composite part forming system

A surface treatment support structure assembly for treating a contoured surface includes a support structure array formed from a plurality of base structures, each base structure being operably coupled with respect to one another and configured to slide along a longitudinal axis and rotate about a laterally translating axis which is perpendicular to the longitudinal axis. The support structure array further includes at least one applicator head coupled to each base structure of the support structure array, each of the at least one applicator head being configured to treat the contoured surface. Additionally, a base structure actuator is operatively coupled to and configured to manipulate each base structure along the longitudinal axis and the laterally translating axis such that the support structure array is adjusted relative to the contoured surface.

Variable cross-section compliance mechanism

An apparatus for forming a material layer onto a form tool may include at least one nosepiece configured to laterally sweep a ply carrier onto a form tool contour. The apparatus may include a pair of tension arms configured to support opposing lateral sides of a ply carrier having a material layer mounted to a lower surface thereof. The apparatus may include one or more actuators configured to position the tension arms during forming of the ply carrier to the form tool contour. The one or more actuators may be configured to sense and control lateral tension in the ply carrier during forming of the ply carrier to the form tool contour.

Apparatus and method for automated layup of composite structures

A mobile vehicle is used to place, compact and inspect composite plies at selected locations on a tool. The vehicle includes an on-board supply of composite plies, a transfer platen for transferring plies to the tool, a compactor for compacting plies on the tool, and an inspection device for inspecting plies on the tool, each operated and manipulated by an on-board manipulator such as a robot.

Mobile system for automated layup and compaction of composite laminates

Apparatuses and methods for forming a joggle and a longitudinal ridge in a multi-ply composite charge are disclosed. Charges may be formed in a forming press that comprises a joggled die, with a longitudinal ridge and a joggle that crosses the longitudinal ridge, and a conforming die, with a series of longitudinally-spaced die fingers. The die fingers include pairs of die members configured to move laterally between a closed position and an open position, with each die member configured to tilt longitudinally.

Forming presses and methods for forming joggled, stiffened composite structures

In an embodiment of the invention, there is provided an apparatus for application and accurate positioning of at least one graphic image on a large contoured surface, comprising a flexible-rail positioning system mounted on a portion of the surface on which the graphic image is to be applied, a graphic image application system, software to operate the positioning system, and software to operate the graphic image application system. In another embodiment of the invention, there is provided a method of applying and accurately positioning at least one graphic image on a large contoured surface.

Apparatus for application and accurate positioning of graphics on a surface

There is provided a method of applying an accurately positioning at least one graphic image on a large contoured surface using an apparatus comprising a flexible-rail positioning system mounted on a portion of the surface on which the graphic image is to be applied, a graphic image application system, software to operate the positioning system, and software to operate the graphic image application system.

Method for application and accurate positioning of graphics on a surface

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Seattle, WA, United States of America

Silas Lawton Studley