Laying die includes an attaching element having an inlet port for receiving positively pressurized gas; and a carrier body made from an elastically deformable material and attached on a lower side of the attaching element. The carrier body includes passages enabling a gas flow between the attaching element and the lower side of the carrier body opposed to the attaching element. The attaching element houses a flow path arranged to receive pressurized gas from the inlet port and a longitudinal pathway extending from the lower side of the attaching element towards an upper side of the attaching element. The flow path discharges into the longitudinal pathway at a junction section, which is arranged such that pressurized gas discharging into the longitudinal pathway creates a negative pressure and comprises a curved deflection surface curved towards the upper side of the attaching element.

Laying die includes an attaching element having an inlet port for receiving positively pressurized gas; and a carrier body made from an elastically deformable material and attached on a lower side of the attaching element. The carrier body includes passages enabling a gas flow between the attaching element and the lower side of the carrier body opposed to the attaching element. The attaching element houses a flow path arranged to receive pressurized gas from the inlet port and a longitudinal pathway extending from the lower side of the attaching element towards an upper side of the attaching element. The flow path discharges into the longitudinal pathway at a junction section, which is arranged such that pressurized gas discharging into the longitudinal pathway creates a negative pressure and comprises a curved deflection surface curved towards the upper side of the attaching element.

Systems and methods are provided for adjustable tooling. One embodiment is a method that includes laying up a laminate of fiber reinforced material onto a continuous surface that has a convex profile and that comprises a first contoured surface of a fixed mold of a composite layup tool and a second contoured surface of a movable mold of the composite layup tool. The method also includes displacing the movable mold in a direction that is at least partially towards the fixed mold, breaking the continuous surface and releasing the laminate from the composite layup tool.

Systems and methods are provided for adjustable tooling. One embodiment is a method that includes laying up a laminate of fiber reinforced material onto a continuous surface that has a convex profile and that comprises a first contoured surface of a fixed mold of a composite layup tool and a second contoured surface of a movable mold of the composite layup tool. The method also includes displacing the movable mold in a direction that is at least partially towards the fixed mold, breaking the continuous surface and releasing the laminate from the composite layup tool.

There is provided a forming system for forming a contoured composite structure having a complex curved configuration. The forming system includes a receiving station having a receiving assembly to receive a composite charge to be formed. The forming system includes a forming station having a forming assembly. The forming assembly includes a gantry assembly, an upper die assembly movably coupled to the gantry assembly, a lower die assembly coupled to a floor support beam positioned between the gantry assembly, and one or more pick-and-place devices movably coupled to the gantry assembly. The upper die assembly is separate from, and independently movable with respect to, the lower die assembly. The pick-and-place device(s) are designed to move the composite charge, and the contoured composite structure. The forming system includes a tray station having a tray assembly designed to receive the contoured composite structure from the forming station.

Auto-aligning vacuum presses, that include a mobile assembly with a first platen, a vacuum docking station with a second platen, a first locating device to guide the mobile assembly to a desired location along the Y-axis as the mobile assembly moves along the X-axis into the vacuum station, and a second locating device to guide one of the first and second platens along the Z-axis into sealing engagement with the other platen.

A ply transporting and compacting apparatus comprises a rigid frame, a top-layer sheet of flexible rubber material fastened to the frame, and a bottom-layer sheet of perforated flexible rubber material having openings. The apparatus also comprises a middle-layer sheet of flow media material disposed in a first plenum area that is defined between the top and bottom layer sheets. The apparatus further comprises a moving device coupled to the frame and arranged to lower the frame and sheets onto a composite ply at a trimming location to pick up the composite ply with a suction force when a vacuum is drawn in the first plenum area to create the suction force through the openings of the bottom-layer sheet.

A method is provided for fabricating a composite ply layup with a desired shape. The method includes moving a shuttle having a sheet of elastic material into engagement with at least one composite ply at a ply pickup station, and picking up the at least one composite ply with the shuttle. The method also includes transporting the shuttle and the at least one composite ply from the ply pickup station to a forming station, and moving the shuttle and the at least one composite ply into engagement with a forming tool at the forming station or any previously laid plies on the forming tool. The method further includes compacting the at least one composite ply on the forming tool or any previously laid plies on the forming tool with the shuttle to form the composite ply layup with the desired shape.

Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.

Systems and methods for manufacturing a composite member. The system and methods are configured to move different types of composite plies from different supply stations. The composite plies are moved along a conveyance member and then with a transfer station to a forming tool. One or more forming members form the composite plies onto the forming tool.