A trailing edge for a composite multispar integrated lifting surface includes a first C-shape composite form that includes a web and two flanges. The web forming a portion of the rear spar of a torsion box. The two flanges extending along a skin chordwise direction. A second C-shape composite form includes a web and two flanges. The web forms an auxiliary spar. The flanges extend along the skin chordwise direction. The first C-shape composite form and the second C-shape composite form forming a first auxiliary cell and a second cell. The first auxiliary cell is delimited by the first C-shape composite form and the second C-shape composite form. The second cell is an open cell delimited by the second C-shape composite form.

A harness routing electrically connects a rear fuselage section of an aircraft and a trimmable Horizontal Tail Plane (HTP) installed at this rear section. The aircraft rear section includes a first clipping point wherein the harness is attached to a fuselage frame located in front of the torsion box front spar, and a second clipping point wherein the harness is attached to a front spar of the HTP torsion box. The second clipping point is located downstream the first clipping point from the fuselage towards the torsion box interior, and the harness passes through the front spar towards the interior of the torsion box downstream the second clipping point. The harness installation and routing is optimized, in order to reduce harness length and weight, but at the same time assuring that any damage to the harness cables are prevented during the entire aircraft operative life.

A method of manufacturing a shim and related systems and equipment. A mechanical tool inserted into a shim space defined between two or more components with the mechanical tool in a first configuration. The mechanical tool is free of measurement electronics. The mechanical tool, while in the shim space, is modified such that the mechanical tool assumes a second configuration to establish a plurality of model points corresponding to a boundary surface of the shim space. The mechanical tool is removed from the shim space while maintaining the mechanical tool in the second configuration. Using a measurement station distinct from the tool, the positions of the model points are electronically measured while the mechanical tool is both disposed outside of the shim space and in the second configuration. Machining instructions are generated based on the measured positions. A shim is fabricated based on the generated machining instructions.

A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structure based on the program, positioning the third structure on the first and second structures such that the third plurality of holes in the third structure are aligned with the first and second plurality of pre-drilled holes in the first and second structures, and inserting fasteners through the third plurality of holes and the first and second plurality of predrilled holes that are aligned with the third plurality of holes to secure the second structure to the first structure using the third structure.

Methods and systems, and components made according to the methods and systems, are disclosed relating to improved methods for fabricating resin-containing composite prepreg materials, wherein the prepreg plies are treated with a particulate material to achieve predetermined spatially variable shear and tack values at a predetermined location on at least one prepreg ply surface of at least one prepreg ply.

Described herein are aircraft, comprising rear spar integration assemblies, and methods of manufacturing these aircraft. Specifically, an aircraft comprises a keel beam and a center wing box, comprising a rear spar. The rear spar is attached to the keel beam using a rear spar integration assembly. The assembly comprises a rear spar stiffener, attached to the rear spar, and having a stiffener load axis. The assembly also comprises and a keel beam fitting, attached to the keel beam, and having a fitting load axis. The rear spar stiffener is also attached to the keel beam fitting, e.g., using splice plates. More specifically, the fitting load axis is offset relative to the stiffener load axis along the primary axis of the aircraft. This offset is designed to compensate for a bending moment at the keel beam-rear spar interface, which allows reducing the size and/or the number of fasteners needed.

Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.

A method of manufacturing a panel assembly includes supporting the panel assembly in a free state using a holding fixture. The panel assembly has a skin panel, and sacrificial material coupled to a skin panel inner surface. The method includes acquiring a free state outer surface contour of the panel assembly by scanning a skin panel outer surface while the panel assembly is supported by the holding fixture. The method also includes developing a numerically controlled (NC) machining program having cutter paths configured for machining the interface locations to an inner surface contour that reflects nominal thicknesses of the panel assembly based off of the free state outer surface contour. In addition, the method includes machining the sacrificial material at the interface locations by moving a cutter along the cutter paths while the panel assembly is supported by the holding fixture.

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.

A convertible aircraft system is provided that can convert to a helicopter configuration, an airplane configuration, or a gyroplane configuration before, during, or after flight. The convertible aircraft system includes a fuselage, a proximal flight assembly, a distal flight assembly, a support spar, and a tail assembly. The fuselage is the main structural body of the present invention. The proximal flight assembly and the distal flight assembly are the flight system of the present invention. The support spar provides an axis of rotation and a pole support for the proximal flight assembly and the distal flight assembly. The tail assembly provides stability during flight of the present invention. In more detail, the tail assembly may comprise at least one vertical stabilizer, at least one horizontal stabilizer, and at least one rudder in order to provide stability during flight of the present invention.