Disclosed herein are systems and methods for manufacturing a part. An example method comprises heating a consolidated laminate sheet, comprising multiple plies each made of fibers embedded in a thermoplastic resin, to a heated temperature below a melting temperature of the thermoplastic resin to form a heated consolidated laminate sheet. The method also comprises forcing the heated consolidated laminate sheet against a contoured forming surface of a mold until a shape of the heated consolidated laminate sheet corresponds with a contoured shape of the contoured forming surface of the mold.

A method of forming a composite structure is presented. A charge is placed on a charge support surface of a charge forming table in a planar orientation, the charge support surface formed by a plurality of surfaces of a plurality of charge forming fingers. A number of charge forming fingers of the plurality of charge forming fingers is actuated to form a curvature into the charge. The charge having the curvature is removed from the charge forming table. The charge having the curvature is placed onto a tool having a matching surface curvature.

The disclosure features systems, devices, and methods of sectioned compaction of composite materials for large parts. An example system includes a mold assembly, including a bottom wall, one or more side walls coupled to the bottom wall, one or more pistons, wherein the bottom wall, the one or more side walls, and the one or more pistons at least partially define a mold cavity, and wherein each of the one or more pistons are independently movable to reduce the volume of the mold cavity; and a plurality of fasteners configured to selectively immobilize the one or more pistons; and a compression actuator configured to sequentially advance the pistons from an initial position to an actuated position to compress a composite material within the mold cavity.

Flexible molds have an elastic membrane supported by modules, arranged next to one another along a horizontal longitudinal axis of the mold. Each module has traction units, each forming a respective group with a respective thrust unit, with the groups arranged opposite one another at a preset distance. Pairs of traction units are arranged opposite one another in a direction perpendicular to the axis, and the respective thrust units thereof are arranged therebetween. The modules hold the membrane with the mold via reinforced eyelets distributed on both edges parallel to the axis. Each traction unit has linear actuators arranged horizontally and another linear actuator arranged vertically, which together enable movement. The membrane is previously deformed according to an approximation of the prior design of a part to be molded, and prestressed according to a mathematical prediction of the deformation thereof after receiving a conglomerate in liquid or plastic state.

A tool, in particular for encapsulating or casting rotors of electric machines, having an arrangement space which extends along a longitudinal axis and is designed to arrange and encapsulate or cast a component, wherein the arrangement space is delimited at least in sections by at least one adjusting tool, the position of which can be adjusted in such a way that a size of the arrangement space can be changed.

A conformable apparatus for treating a composite material. The conformable apparatus includes a contact layer that is conformable and includes a plurality of contact elements. Each contact element of the plurality of contact elements includes a first major side, a second major side opposed from said first major side, and at least one side surface extending between said first major side and said second major side. The contact layer further includes a contact surface at least partially defined by the first major sides of the plurality of contact elements and a backing surface at least partially defined by the second major sides of said plurality of contact elements. The conformable apparatus also includes a backing layer positioned against said backing surface of said contact layer.

A leveler table includes a plate with a flat top work surface that is level in all planes, by locating a circular level recessed within the center of the plate, so that the level indicator of the circular level is in horizontal alignment with the top work surface. By locating the circular level in the middle of the plate, at the same horizontal level as the work surface, this leveler table provides accuracy and repeatability for use of the flat top work surface in manufacturing steps, particularly the forming of parts where repeatability is necessary, such as the in situ forming of an automotive windshield sensor pad in an open ended package supported on the flat top surface.

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.

Systems and methods for reusable molding devices in accordance with embodiments of the invention are disclosed. In one embodiment, a reusable molding device is provided comprising: an array comprising a plurality of pixel pins, which are arranged to form a two-dimensional plane and which are each linearly movable to create an impression of a surface of an object, a first pixel guide plate, a second pixel guide plate, a first clamp pressure plate, a second clamp pressure plate, a first clamp screw, wherein the first clamp screw moves the first clamp pressure plate towards the first side of the array, a second clamp screw which moves the second clamp pressure plate towards the second side of the array, a pressure clamp frame enclosing the first and second pixel guide plates and the first and second clamp pressure plates, and a top pressure plate, which includes an injection entrance bore.

A mold assembly may include a mold frame having an opening extending in a plane and a movable mold insert adjuster to move a mold insert having a slot forming protrusion within the plane within opening.