An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Systems, devices, and methods including a leading edge tubular member; an upper tubular member; a lower tubular member; one or more upper rib members connected between the leading edge tubular member and the upper tubular member; one or more lower rib members connected between the leading edge tubular member and the lower tubular member; a rigid sandwich shell disposed between the upper tubular member and the leading edge tubular member; and a sandwich shear web disposed between the upper tubular member and the lower tubular member; where the rigid sandwich shell and the sandwich shear web form a D-shape.

Systems, devices, and methods including one or more rib mounting flanges, where each rib mounting flange comprises: a spar opening configured to receive a main spar of a wing panel; one or more holes for receiving cross-bracing cables; and one or more holes for receiving cross-bracing cables; and one or more holes for connecting the rib mounting flange to an adjacent rib mounting flange.

A foldable wing with foldable trailing edge flap, that includes a main wing and a foldable trailing edge flap. The main wing includes a wing supporting skeleton and a plurality of skin supporting ribs. The foldable trailing edge flap includes a plurality of crank-shaped flap supporting ribs, a flexible flap skin, a connecting shaft, and a return spring. The plurality of crank-shaped flap supporting ribs are hinged with lower surfaces of corresponding plurality of skin supporting ribs through the connecting shaft to form a foldable trailing edge flap supporting skeleton that relies on the plurality of skin supporting ribs. The return spring makes an upper surface of a long side of each crank-shaped flap supporting rib attach closely to a lower surface of each skin supporting rib. The flexible flap skin is attached to an upper surface of the foldable trailing edge flap supporting skeleton.

A bonding tool is described that is used to secure sacrificial pads to bonding locations on a perimeter of a rib during a bonding process. In one embodiment, the bonding tool includes a base member having a rib receptacle dimensioned to receive a rib of a wing, a plurality of compression forms disposed around at least a portion of the rib receptacle and proximate to a perimeter of the rib, where the compression forms include a plurality of sacrificial pads that face towards bonding locations on the perimeter of the rib, and at least one bladder proximate to the compression forms that expands between a wall of the base member and the compression forms to press the sacrificial pads against the bonding locations while the sacrificial pads bond to the bonding locations.

An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

A connection rod comprising first and second connection elements. The first element comprises a shaft, a first connector at a shaft proximal end and a piercing body at a shaft distal end. The second element comprises a hollow casing with a fluid barrier therein, which, when intact, forms first and second reactive fluid material reservoirs, both within the casing. The second connection element comprises a second proximal end connector and a distal end inlet hole to the second reservoir. The piercing body fits within the casing and the shaft slidably engages the inlet hole such that the first element slides relative to the second element. The piercing body pierces the fluid barrier such that the reactive fluid materials mix between the reservoirs and react to form a reacted solid material restraining the piercing body within the casing to prevent relative sliding between the first and the second connection elements.

A wing having a main wing section with a forward spar and an aft spar extending through an internal cavity. The forward and aft spars are spaced apart and delimiting a dry segment of the internal cavity. A winglet is rotatably coupled to the main wing section by a cant hinge defining a cant axis about which the winglet rotates relative to the main wing section between an extended position in which the winglet is aligned with the main wing section, and a folded position in which the winglet is rotated about the cant axis. A linkage assembly disposed in the dry segment is pivotably mounted to one of the forward and aft spars and is coupled to the cant hinge. The linkage assembly is displaceable to apply a force to move the winglet between the extended position and the folded position during flight of the aircraft.

Seal plates are typically mounted over stringer-receiving openings in aircraft ribs. A sealing tool for sealing a stringer-receiving opening in an aircraft rib is disclosed. The sealing tool includes a seal member arranged to seal a gap formed by the opening between the stringer and the rib. An intermediate member is configured to be adjustably mounted on the rib. The adjustable member receives and aligns the seal member over the gap.

Seal plates are typically mounted over stringer-receiving openings in aircraft ribs. A sealing tool for sealing a stringer-receiving opening in an aircraft rib is disclosed. The sealing tool includes a seal member arranged to seal a gap formed by the opening between the stringer and the rib. An intermediate member is configured to be adjustably mounted on the rib. The adjustable member receives and aligns the seal member over the gap.