The Boeing Company

Stephen J Dostert

Jeffrey Lawrence Miller

James R Kendall

Gary D Oakes

Scott M Spencer

Michael Honea

Michael J Louderback

Vivek Kapila

A method for contour forming in a fiber placement system. The method includes painting multiple sliced layers on a stationary form to create a composite component. The sliced layers include multiple hoop tows. One or more overlap splices are formed in each of the hoop tows. The method includes applying a layup heat to multiple target areas on the sliced layers during the painting. The target areas are spatially arranged to permit a slippage in the splices. The method further includes draping the composite component on a curved tool with the hoop tows oriented perpendicular to an axis of curvature of the curved tool, and applying a curing heat to the composite component after the composite component has been contoured by the curved tool. The curing heat inhibits a further slippage in the overlap splices.

Contour forming in fiber-placement system

A part analysis tool is used to analyze aspects of a composite part. The part analysis tool includes a verification control unit that compares numerical control data used to control operation of a forming system that is used to form the composite part to computer-aided design (CAD) data that includes an authoritative part definition for the composite part. The verification control unit determines whether the numerical control data is within one or more conformance thresholds related to the CAD data. The part analysis tool may also include an inspection control unit that compares inspection data of one or more plies of the composite part to the CAD data. The inspection control unit determines whether the inspection data is within the conformance threshold(s) related to the CAD data.

System and method for validating and inspecting composite parts

A computer-implemented method is disclosed that is usable during production of an assembly using at least a first machine tool. The method comprises retrieving a predetermined production plan for the assembly, wherein the predetermined production plan comprises a plurality of operations using the first machine tool; acquiring input data to determine a production deviation from the predetermined production plan; determining, responsive to determining the production deviation, a modified production plan for the assembly by substituting one or more substitute operations for one or more of the plurality of operations of the predetermined production plan; and transmitting instructions to the first machine tool corresponding to the one or more substitute operations of the modified production plan.

Dynamic modification of production plans responsive to manufacturing deviations

A randomly damaged area of a one-piece composite component of an aircraft is repaired according to a method herein. The damaged area covers skin and underlying stiffening substructure of the component. The method includes generating a design of a customized composite replacement panel for replacing the damaged area. The design includes replacement skin and underlying co-cured replacement stiffening substructure. The method further includes fabricating the composite replacement panel according to the design.

Large area repair of composite aircraft

A method of fabricating a composite part including reinforcing fibers comprises fabricating a masterless layup mandrel tool at a fabrication site. The tool includes a composite face sheet that provides a layup surface. The method further comprises using the masterless tool at that site to form a layup of the reinforcing fibers.

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Edmonds, WA, United States of America

Stephen J Dostert