The Boeing Company

Trevor Lee Howard

David J Sundquist

Steven J Burpo

Kurtis Shuldberg Willden

Eric Eldon Deck

Robert A Rapp

Sarah Vaselaney

Joshua K Hillam

Zachary Benjamin Renwick

Allyson Antonio

David John Sundquist

A drape forming apparatus includes a forming tool having a first forming surface and a second forming surface nonplanar with the first forming surface. A tray is spaced apart from the forming tool and is configured to pivot about a hinged end from a first position to a second position under an applied force such that a distal end moves away from the forming tool. A first side of the tray faces a first heat source when the tray is in the first position, and a second heat source is disposed at a second side of the tray. A device for use in forming the composite structure includes a standoff and the tray, and a heat source is secured to the second side of the tray. A method of forming a composite structure includes heating both sides of the composite material with the first and second heat sources.

Drape forming apparatus and device, and method of forming a composite structure

An apparatus for hot drape forming a part includes a plurality of pyrometers, a bladder covering a formable material, and a pyrometer control medium positioned between the plurality of pyrometers and the formable material. The plurality of pyrometers are configured to measure a temperature of the pyrometer control medium.

Pyrometer control for hot drape formers

A composite structure includes a base structure, a core disposed on the base structure, the core having a non-uniform contour relative to the base structure, a layered cover material disposed on the base structure covering the core, the layered cover material conforming to the non-uniform contour of the core and having at least one overlay ply, each of the at least one overlay ply having at least one slit cut through fibers of the respective overlay ply, and at least one cover ply having a shape that spans the at least one slit, and being configured to transfer a load across the at least one slit.

Method of producing cored composite parts

A drape forming apparatus for use in forming a composite structure. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool receives at least one layer of composite material over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.

Apparatus and method of forming a composite structure

A drape forming apparatus for that includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material over the upper forming surface. The apparatus includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot receives a flange portion of the layer of composite material, and the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus includes a pressurized bladder that extends over the forming tool and the upper plate. The pressurized bladder forces the flange portion against the side forming surface as the flange forming device translates relative to the forming tool.

Growing community of inventors

St. Louis, MO, United States of America

Trevor Lee Howard