The Boeing Company

William Stahl Hollensteiner

Benjamin Jeffrey Stephenson

Kurtis Shuldberg Willden

Brian Gregory Robins

Darrell Darwin Jones

Daniel M Rotter

Joseph Daniel Brennan

Jennifer Sue Noel

William Henry Ingram, Jr

Scott K Frankenbery

Kenneth Marvin Dull

Dennis James Hanks

Gwen Marie Lanphere Gross

Donald Chester Darrow

Hugh A Yap

Shane Edward Arthur

John Dempsey Morris

Jonathan A Santiago

Charles William Thomas

Samuel Ray Stewart

James B Castle

Timothy David Aquino

Jake Adam Reeves

Megan Elizabeth Bliss

Amy E Bahe

John R Henry

Sebastian Nervi

John R Aubin

Vincent R Noble

Jordan McHale Edginton

Cody Allan Beagley

A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.

Multi-planar fiber matrix tool-less preform for resin infusion

A structure comprising a plurality of walls defining a bladder cavity, the bladder cavity comprises an initial cross section size. A first plurality of wave features provided along at least one of the plurality of walls defining the bladder cavity. In one arrangement, the first plurality of wave features allow the structure to expand from the initial cross section size to a second cross section size after the structure becomes inflated during a composite charge cure, the second cross section size larger than the initial cross sectional size.

Bladder system for curing composite parts

A vacuum port base comprises an upper face, a lower face, a first channel, and a second channel. The upper face is configured to interface with a vacuum port. The lower face is configured to interface with a surface of a tool. The first channel formed in the lower face is configured to receive an edge breather. The second channel formed within the vacuum port base is configured to receive the vacuum port such that the vacuum port is in fluid communication with the first channel and the edge breather to remove gases from a composite structure.

Vacuum port base

A method for predicting distortion and residual stress in a workpiece resulting from a peening process may include the steps of providing a coupon including residual stress induced in a coupon surface by the peening process, calculating a moment coefficient representative of residual stress induced in the coupon surface, calibrating a stress function to the moment coefficient, applying the stress function to a workpiece model of the workpiece, and computing at least one of predicted distortion and residual stress of the workpiece resulting from application of the calibrated stress function to the workpiece model.

System and method for predicting distortion of a workpiece resulting from a peening machine process

Systems and methods are provided for curing composite products. One exemplary embodiment is an edge breather for composite manufacturing. The edge breather is formed of a rigid material and includes an elongated body having a top open structure with a cross section that defines an arch. The edge breather also includes hollow passageways within the elongated body that are underneath the top structure and travel along a length of the elongated body. The top open structure defines multiple openings forming an open mesh through which air may enter.

Edge breathers for composite products

An apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.

Composite stiffener positioning and vacuum bag installation device

Methods, systems and apparatuses are disclosed for making and post-processing a 3-D printed object for laminate-forming tooling, and components made using post-processed 3-D printed laminate-forming tooling.

Method and apparatus for high-temperature post-curing of UV-cured photopolymers

A composite layup is formed on a tool and placed on a contoured part. The tool is contoured to substantially match the contour of the part. A set of location data is generated which represents the location of the part in space relative to the tool. An automated manipulator uses the location data to move the tool into proximity to the part and place the contoured layup on the part.

Method for forming and applying composite layups having complex geometries

A composite part charge having an internal cavity is placed on a tool and covered by a vacuum bag for autoclave curing. A bladder is placed in the cavity to react autoclave pressure on the charge. The bladder is coupled with a flexible fluid reservoir located beneath the vacuum bag. The bladder is pressurized by autoclave pressure applied through the vacuum bag to the flexible fluid reservoir.

Non-vented bladder system for curing composite parts

A method and apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.

Composite stiffener positioning and vacuum bag installation

A method for manufacturing composite parts. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool for a composite part. The inner mold line tool may be positioned with the composite part inside an outer mold line tool. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. The inner mold line tool and the temporary removal layer may be removed from inside of the outer mold line tool after transferring the composite part and the temporary removal layer to the outer mold line tool.

Growing community of inventors

Kent, WA, United States of America

William Stahl Hollensteiner