A frame component for a frame of a fuselage structure of an aircraft includes a central web extending along a longitudinal direction and having an inner edge region with respect to a radial direction running transversely with respect to the longitudinal direction and an outer edge region with respect to the radial direction. An inner web is bent from the inner edge region of the central web towards a first side. An outer web is bent from the outer edge region of the central web towards the first side. The central web, the outer web and the inner web are produced integrally from a metal sheet and together define a C-shaped cross section of the frame component. At least one stringer recess is formed in the outer web and in the outer edge region of the central web. The central web has, in the region of the stringer recess, a first reinforcing formation which forms a protrusion on the first side of the central web.

Systems and methods are provided for fabricating a preform for a fuselage section of an aircraft. The method includes advancing a series of arcuate mandrel sections in a process direction through an assembly line, laying up fiber reinforced material onto the arcuate mandrel sections via layup stations, uniting the series of arcuate mandrel sections into a combined mandrel; and splicing the fiber reinforced material laid-up onto the arcuate mandrel sections.

A vented hat stringer for an aircraft comprises a first hat-stringer leg with a first-hat-stringer-leg surface, a second hat-stringer leg with a second-hat-stringer-leg surface, a first hat-stringer sidewall, a second hat-stringer sidewall, and a hat-stringer connecting wall, comprising a hat-stringer-connecting-wall surface and a virtual hat-stringer-connecting-wall symmetry plane, passing through hat-stringer connecting wall. The vented hat stringer further comprises a ventilation opening, extending through at least one of the first hat-stringer sidewall or the hat-stringer connecting wall, or extending through at least one of the second hat-stringer sidewall or the hat-stringer connecting wall. The ventilation opening defines a ventilation-opening centerline, wherein the ventilation-opening centerline does not coincide with the virtual hat-stringer-connecting-wall symmetry plane.

Additive manufactured airframe structure having a plurality of additive manufactured airframe segments operable to be linked together in an assembled direction. Each of the plurality of additive manufactured airframe segments are separate from one another in an unassembled configuration. Plurality of reinforcement elements operable to be received in a receiving portion of the plurality of airframe segments and extending through the plurality of airframe segments in a normal direction. Receiving portion is located on the interior of a respective one of the plurality of airframe segments.

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.

There is provided a forming apparatus for forming a high contour composite structure. The forming apparatus includes an upper die and a lower die between which a composite charge is formed. The forming apparatus further includes a plurality of load cells, a control system, and an overlay tool assembly coupled to the upper die. The overlay tool assembly has scalloped sections positioned between pairs of the plurality of load cells, and positioned against portion(s) of the composite charge. The composite charge has ply discontinuity features through the one or more portions. The overlay tool assembly denies pressure and a through thickness compaction to the one or more portions of the composite charge during a forming process, to allow one or more plies in the one or more portions to move after the forming process, and to enable in-plane bending of the high contour composite structure in post-forming operations.

An unmanned aerial vehicle (UAV) includes a fuselage assembly, a further portion that attaches with the fuselage assembly, and a propulsion assembly coupled with the further portion. The propulsion assembly is constructed and arranged to provide propulsion for the UAV. The fuselage assembly includes a fuselage body constructed and arranged to operate as a forward portion of the UAV, lateral stringers coupled with the fuselage body and extending laterally along the fuselage body, and a set of interchangeable covers to cover at least a portion of a payload bay opening defined by the fuselage body. Utilizing such a fuselage assembly offers a highly configurable mounting architecture to accommodate a wide variety of payloads.

Described herein are methods of forming uncured sealant assemblies and also methods of forming seals between various parts using such assemblies. In some examples, an uncured sealant assembly comprises two protective layers and an uncured sealant layer, disposed in between. The uncured sealant assembly is stored and provided at a cure-inhibiting temperature, selected to minimize the curing rate of the uncured sealant layer. The size and the shape of the uncured sealant layer are specifically selected to ensure the complete coverage of the faying surfaces, filling of all gaps and voids between the faying surfaces, and controlling the shape and size of uncured sealant squeeze out between the faying surfaces. In some examples, the size and shape of the uncured sealant layer maybe be specifically selected to have no uncured sealant squeeze out between parts.

Provided are stiffened stringer panels with integrated plank structures. An example composite panel comprises a skin member having an inner surface, and a plank on the inner surface. The plank comprises a set of layered laminate plies and extends from a first side to a second side. Each laminate ply of the set of layered laminate plies is sized to form a desired geometric profile for each of the first side and the second side. The composite panel further comprises a stringer including a cap portion that spans from the first side of the plank to the second side of the plank to form a first flange portion and a second flange portion, respectively, on the inner surface of the skin member. Base segments of the cap portion conform to the desired geometric profile of respective first and second sides of the plank.

Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.