A method for forming large titanium parts includes forming bends into a titanium plate for form a bent part. The bent part is then roll-formed to form contours into the bent part. The surfaces of the contoured part are rough-machined, and the part is then secured to a bladed form fixture. The bladed form fixture comprises a plurality of header boards that secure the part to the fixture. The fixture part is placed in a thermal vacuum furnace and a stress-relieving operation is performed. The part is removed from the fixture and final machining takes place.

A structure for an aircraft fuselage, the structure comprising a skin having an outer face and an inner face machined as a grid-stiffened panel, a plurality of frames, each frame shaped as the cross section of the fuselage and the frames being arranged one after the other along a longitudinal direction of the fuselage. The outer perimeter of each frame is secured to the inner face, a plurality of stringers extend parallel to the longitudinal direction, each stringer extending across multiple frames, passing through these at an opening provided to that end in each frame, and each stringer is pressed against the inner face and secured thereto. In the upper part and in the lower part of the fuselage, a torsion box is provided extending parallel to the longitudinal direction, each torsion box comprising a horizontal plate and tabs which secure the plate to the inner face.

A structure for an aircraft fuselage, the structure comprising a skin having an outer face and an inner face machined as a grid-stiffened panel, a plurality of frames, each frame shaped as the cross section of the fuselage and the frames being arranged one after the other along a longitudinal direction of the fuselage. The outer perimeter of each frame is secured to the inner face, a plurality of stringers extend parallel to the longitudinal direction, each stringer extending across multiple frames, passing through these at an opening provided to that end in each frame, and each stringer is pressed against the inner face and secured thereto. In the upper part and in the lower part of the fuselage, a torsion box is provided extending parallel to the longitudinal direction, each torsion box comprising a horizontal plate and tabs which secure the plate to the inner face.

Systems, devices, and methods for fabricating finished parts include a system that includes a plurality of die assemblies located at a plurality of respective locations, each die assembly being configured to fabricate a respective finished part. The system further includes a movable gantry press and a robot, each configured to move between the plurality of respective locations. The system further includes a controller configured to receive a input to fabricate a finished part and identify a die assembly of the plurality of die assemblies. The controller is further configured to instruct the movable gantry press and the robot to move to the location of the die assembly. The controller is further configured to instruct the robot to load a blank into the die assembly, and instruct the movable gantry press to operate the die assembly to fabricate the finished part.

Systems, devices, and methods for fabricating finished parts include a system that includes a plurality of die assemblies located at a plurality of respective locations, each die assembly being configured to fabricate a respective finished part. The system further includes a movable gantry press and a robot, each configured to move between the plurality of respective locations. The system further includes a controller configured to receive a input to fabricate a finished part and identify a die assembly of the plurality of die assemblies. The controller is further configured to instruct the movable gantry press and the robot to move to the location of the die assembly. The controller is further configured to instruct the robot to load a blank into the die assembly, and instruct the movable gantry press to operate the die assembly to fabricate the finished part.

A method for changing the shape of a sheet-like workpiece, which has a mould recess formed by reducing the thickness of the material, includes arranging the workpiece on at least two spaced-apart supporting elements of a machine bed, and forming the workpiece into a final shape by step-by-step free bending. The steps of bending a part of the workpiece by lowering an upper die between the supporting elements from a waiting position into a forming position, raising the upper die into the waiting position and moving the position of the workpiece relative to the machine bed in at least one infeed direction are performed repetitively. Before the workpiece is formed into the final shape, a filling element, which is adapted to the mould recess and designed to make up the material thickness, is produced and is arranged in the region of the mould recess. An arrangement is also provided.

A method for changing the shape of a sheet-like workpiece, which has a mould recess formed by reducing the thickness of the material, includes arranging the workpiece on at least two spaced-apart supporting elements of a machine bed, and forming the workpiece into a final shape by step-by-step free bending. The steps of bending a part of the workpiece by lowering an upper die between the supporting elements from a waiting position into a forming position, raising the upper die into the waiting position and moving the position of the workpiece relative to the machine bed in at least one infeed direction are performed repetitively. Before the workpiece is formed into the final shape, a filling element, which is adapted to the mould recess and designed to make up the material thickness, is produced and is arranged in the region of the mould recess. An arrangement is also provided.

A method of manufacturing a multi-sided or otherwise relatively three-dimensional formed structure for, e.g., an aerospace vehicle. A relatively planar base structure is constructed using a first construction technique. Features (e.g., ribs) are incorporated into the base structure using a second construction technique (e.g., additive or subtractive manufacturing) to create an intermediate structure. The intermediate structure is folded along fold-lines or otherwise physically formed to create the formed structure, such that some of the features are located within an internal space defined by the formed structure. Joints between the sides of the formed structure are welded, fastened, or otherwise secured. Separately constructed additional elements (e.g., bulkheads) may be incorporated into the structure. A closeout element may be added to the formed structure to further define and close the internal space. Throughout the process, the structures, features, and elements may be refined to desired tolerances.

Systems and methods are provided for designing composite parts. One embodiment is a laminate shear forming machine configured to shape a composite charge. The laminate shear forming machine includes a layup mandrel including a surface for shaping the composite charge, forming members configured to press the composite charge against the surface of the layup mandrel to shape the composite charge, and pressure sensing strips configured to measure pressure between the forming members and the composite charge. The laminate shear forming machine also includes a forming controller coupled to the pressure sensing strips and configured to determine that at least one forming member is applying pressure to the composite charge outside a pressure range, and to direct the at least one forming member to adjust from a first position to a second position to apply pressure to the composite charge within the pressure range.

Systems and methods are provided for designing composite parts. One embodiment is a laminate shear forming machine configured to shape a composite charge. The laminate shear forming machine includes a layup mandrel including a surface for shaping the composite charge, forming members configured to press the composite charge against the surface of the layup mandrel to shape the composite charge, and pressure sensing strips configured to measure pressure between the forming members and the composite charge. The laminate shear forming machine also includes a forming controller coupled to the pressure sensing strips and configured to determine that at least one forming member is applying pressure to the composite charge outside a pressure range, and to direct the at least one forming member to adjust from a first position to a second position to apply pressure to the composite charge within the pressure range.