A system and a method for manufacturing laminated composite components is described. The system may include a cutting station configured to separate component layers from a ply of composition material according to a predefined pattern, a build station configured to stack the component layers according to a predetermined orientation, and a finishing station configured to compact the stacked component layers and provide the laminated composite component to an installation station.

Described are methods and systems for identifying processing locations in composite layups. An optical magnetic marker is magnetically supported by a layup tool at a target position, such that a portion of the marker protrudes above the tool processing surface. When a composite layup is placed onto that surface, the protruding portion extends into the layup at a processing location. When the layup is cured, the marker is permanently embedded into the layup. Separating the cured layup from the tool removes the marker from the tool and allows an additional marker to advance into the target position for processing another layup. The embedded marker or, more specifically, marker's reflective surface is used during optical inspection of the layup surface to precisely determine the processing location. In some examples, the marker is consumed while the layup is processed at that location,

A process for room temperature substrate bonding employs a first substrate substantially transparent to a laser wavelength is selected. A second substrate for mating at an interface with the first substrate is then selected. A transmissivity change at the interface is created and the first and second substrates are mated at the interface. The first substrate is then irradiated with a laser of the transparency wavelength substantially focused at the interface and a localized high temperature at the interface from energy supplied by the laser is created. The first and second substrates immediately adjacent the interface are softened with diffusion across the interface to fuse the substrates.

High-frequency welding method for welding an accessory to a substrate by high-frequency welding machinery which includes a female mold, having a cavity formed by a profile having substantially the same shape and dimensions as the accessory, and a male mold, having a relief formed by a profile having substantially the same shape and dimensions as the accessory. The method includes: mounting the female mold on a movable upper plate of the machinery and the male mold on a fixed lower plate of the machinery, or vice versa, such that the profile of the cavity is aligned in a closure direction of the molds with the profile of the relief. The method further includes: positioning the accessory on the relief or in the cavity; positioning the substrate above the accessory; moving the upper plate towards the lower plate; supplying high-frequency welding energy to the upper plate and/or to the lower plate.

A joining system includes a holding fixture assembly configured to hold a fuselage skin. The stringers are temporarily attached to the fuselage skin. The joining system includes an upper beam assembly including an upper beam and a lower beam assembly. The lower beam assembly includes a lower beam and at least one lower heating element. The holding fixture assembly is coupled to the upper beam assembly. The holding fixture assembly is coupled to the lower beam assembly. The upper beam is movable relative to the lower beam to clamp the at least one of the plurality of stringers and the fuselage skin together prior to and during welding.

A system for laser processing includes a plate assembly having a first plate, a second plate secured to the first plate, and a pressure chamber located between the plates, a connector extending into and in fluid communication with the pressure chamber, and a fixture having a first end attached to the second plate of the plate assembly, a second end having surface having at least one opening and shaped to fit a part to be retained and laser processed, and a conduit extending therethrough in fluid communication with the pressure chamber and the at least one opening. During use, a pressure generated by a pump may be communicated to the conduit of the fixture through the pressure chamber to provide pressure (e.g., a suction effect) at the opening(s) to secure the part in place, e.g., with respect to another part, so they can be laser processed.

A system for laser processing includes a plate assembly having a first plate, a second plate secured to the first plate, and a pressure chamber located between the plates, a connector extending into and in fluid communication with the pressure chamber, and a fixture having a first end attached to the second plate of the plate assembly, a second end having surface having at least one opening and shaped to fit a part to be retained and laser processed, and a conduit extending therethrough in fluid communication with the pressure chamber and the at least one opening. During use, a pressure generated by a pump may be communicated to the conduit of the fixture through the pressure chamber to provide pressure (e.g., a suction effect) at the opening(s) to secure the part in place, e.g., with respect to another part, so they can be laser processed.

The invention relates to a fastening element for fastening to a workpiece, said fastening element comprising at least a first workpiece element having a first opening and a second workpiece element having a second opening aligned with the first opening, wherein the fastening element has a first contact section having a first contact surface for contact with a region of the first workpiece element surrounding the first opening and a second contact section having a second contact surface for contact with a region of the second workpiece element surrounding the second opening, with the first contact section and the second contact section being connected to one another by means of a reshaping section, and with a rivet section extending from the second contact section in a direction facing away from the reshaping section. The invention further relates to a corresponding component assembly and to a method of manufacturing such a component assembly.

The invention relates to a fastening element for fastening to a workpiece, said fastening element comprising at least a first workpiece element having a first opening and a second workpiece element having a second opening aligned with the first opening, wherein the fastening element has a first contact section having a first contact surface for contact with a region of the first workpiece element surrounding the first opening and a second contact section having a second contact surface for contact with a region of the second workpiece element surrounding the second opening, with the first contact section and the second contact section being connected to one another by means of a reshaping section, and with a rivet section extending from the second contact section in a direction facing away from the reshaping section. The invention further relates to a corresponding component assembly and to a method of manufacturing such a component assembly.

A method for forming a composite part includes positioning a composite ply over a forming surface of a forming tool, moving a forming feature into engagement with the composite ply to yield a formed ply, and, after the moving, securing the formed ply relative to the forming tool.