Systems and methods are provided for dynamically altering the shape of a forming tool for a composite part during forming. An exemplary forming tool includes a main body that holds a first portion of a multi-layer laminate, and a platform that holds a second portion of the laminate aligned with the first portion. The forming tool also includes a biasing device that repositions the second portion with respect to the first portion during forming of the laminate, causing shear stresses between the layers of the laminate.

A fibre placement head includes a roller mount having an axle defining a roller axis, and a hollow roller defining an internal chamber. The roller is mounted on the axle and configured to rotate about the roller axis. The fibre placement head also comprises a pressurised fluid system configured to deliver and discharge pressurised fluid to and from the internal chamber of the roller, to vary a stiffness of the roller by varying a pressure of fluid in the chamber. The fibre placement head may also be included in a fibre placement machine having the fibre placement head, and a method of laying up fibre reinforcement material using the fibre placement head.

A fibre placement head includes a roller mount having an axle defining a roller axis, and a hollow roller defining an internal chamber. The roller is mounted on the axle and configured to rotate about the roller axis. The fibre placement head also comprises a pressurised fluid system configured to deliver and discharge pressurised fluid to and from the internal chamber of the roller, to vary a stiffness of the roller by varying a pressure of fluid in the chamber. The fibre placement head may also be included in a fibre placement machine having the fibre placement head, and a method of laying up fibre reinforcement material using the fibre placement head.

Provided are a method and a device for producing a pultruded material that improve the homogeneity of a thermosetting resin. The device for producing a pultruded material comprises a first opening section, a second opening section, a closing section, a tension-applying section, an impregnating section, and a mold. The first opening section and the second opening section open a bundle of reinforcing fibers and thereby obtain a bundle of reinforcing fibers. The closing section closes the bundle of opened reinforcing fibers and thereby obtains a bundle of reinforcing fibers. The tension-applying section applies tension along the direction in which the reinforcing fibers extend to the bundle of reinforcing fibers that pass through the closing section. The impregnating section impregnates the bundle of reinforcing fibers with a thermosetting resin. The mold pultrudes the bundle of reinforcing fibers that have been impregnated with the thermosetting resin.

Provided are a method and a device for producing a pultruded material that improve the homogeneity of a thermosetting resin. The device for producing a pultruded material comprises a first opening section, a second opening section, a closing section, a tension-applying section, an impregnating section, and a mold. The first opening section and the second opening section open a bundle of reinforcing fibers and thereby obtain a bundle of reinforcing fibers. The closing section closes the bundle of opened reinforcing fibers and thereby obtains a bundle of reinforcing fibers. The tension-applying section applies tension along the direction in which the reinforcing fibers extend to the bundle of reinforcing fibers that pass through the closing section. The impregnating section impregnates the bundle of reinforcing fibers with a thermosetting resin. The mold pultrudes the bundle of reinforcing fibers that have been impregnated with the thermosetting resin.

A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.

A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.

The machine comprises a solid matrix (1), a deformable body (2) joined to the surface of said matrix (1), a shaping mould (3) and a securing system system (5) for the fibre structure (4). The matrix (1) is a solid element having a functional face, the geometry of which depends on the part to be manufactured. The deformable body (2) has an initial geometry that depends on the geometry to be given to the fibre structure (4). The shaping mould (3) has the geometry to be given to the fibre structure (4) during the process of adaptation to the shaping mould (3), and the shaping mould (3) is located such that the deformable body (2) is located between said shaping mould (3) and the matrix (1).

A flexible punch and die are used to form a flat composite laminate charge into a stiffener having a desired cross sectional shape. A desired contour is formed in the stiffener by bending the punch and die. Ply wrinkling is avoided during contouring by maintaining those portions of the stiffener subject to wrinkling in tension as the contouring is being performed. Bridging of the plies during the contouring process is avoided by first contouring those sections of the stiffener that are subject to wrinkling, and then contouring the remaining sections of the stiffener.

A flexible punch and die are used to form a flat composite laminate charge into a stiffener having a desired cross sectional shape. A desired contour is formed in the stiffener by bending the punch and die. Ply wrinkling is avoided during contouring by maintaining those portions of the stiffener subject to wrinkling in tension as the contouring is being performed. Bridging of the plies during the contouring process is avoided by first contouring those sections of the stiffener that are subject to wrinkling, and then contouring the remaining sections of the stiffener.