Provided are methods of forming stiffened stringer panels with integrated plank structures. A skin member having an inner surface is provided. A plank is positioned onto the inner surface of the skin member. The plank extends from a first side to a second side, and each laminate ply of the set of layered laminate plies is sized to form a geometric profile for each of the first side and the second side. Each laminate ply of the set of layered laminate plies is arranged to extend from the first side to the second side. A stringer is placed onto a support tool. The support tool, and the stringer thereon, is positioned upon an uppermost laminate ply of the set of layered laminate plies. The skin member, the plank, and the stringer are joined.

Provided are methods of forming stiffened stringer panels with integrated plank structures. A skin member having an inner surface is provided. A plank is positioned onto the inner surface of the skin member. The plank extends from a first side to a second side, and each laminate ply of the set of layered laminate plies is sized to form a geometric profile for each of the first side and the second side. Each laminate ply of the set of layered laminate plies is arranged to extend from the first side to the second side. A stringer is placed onto a support tool. The support tool, and the stringer thereon, is positioned upon an uppermost laminate ply of the set of layered laminate plies. The skin member, the plank, and the stringer are joined.

A method of manufacturing a composite structure, e.g. wind turbine blade, using reusable and removable perimeter plates to establish air flow channels in conjunction with a vacuum bag and mold. An exemplary setting is the perimeter of large wind blade shells where a perimeter vacuum is used to retain the part in the mold for the bonding process. The reusable plates disclosed herein create air channels whether the vacuum is introduced to the perimeter of the mold: i) through the flange in different locations; or ii) with the use of vacuum lines into the perimeter bag; or iii) built in vacuum channels in the flange of the mold.

Systems and methods for a caul plate for an irregular surface. One embodiment is a caul plate for co-curing or co-bonding a first composite part and a second composite part. A body of the caul plate includes a lower surface to face a top surface of the first composite part, a reference edge to locate the second composite part on the first composite part, and an upper surface that is opposite to the lower surface. The lower surface includes one or more bends to match one or more slopes in the top surface of the first composite part. The one or more bends correspond with ply changes in the first composite part.

Systems and methods for a caul plate for an irregular surface. One embodiment is a caul plate for co-curing or co-bonding a first composite part and a second composite part. A body of the caul plate includes a lower surface to face a top surface of the first composite part, a reference edge to locate the second composite part on the first composite part, and an upper surface that is opposite to the lower surface. The lower surface includes one or more bends to match one or more slopes in the top surface of the first composite part. The one or more bends correspond with ply changes in the first composite part.

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 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 membrane assembly for vacuum bagging includes an elongate sheet of flexible material capable of being rolled up into a cylindrical configuration and unrolled from the cylindrical configuration into a flattened-out configuration, a bistable tape spring attached to or captured by the elongate sheet, and an inflatable tube attached to or captured by the elongate sheet. The bistable tape spring has a first stable state which is a straightened-out state, a second stable state which is a rolled-up state, and a transition state between the first and second stable states. The inflatable tube is sealed at one end and has an orifice at the other end for admission of a fluid therethrough for inflation of the inflatable tube.

A membrane assembly for vacuum bagging includes an elongate sheet of flexible material capable of being rolled up into a cylindrical configuration and unrolled from the cylindrical configuration into a flattened-out configuration, a bistable tape spring attached to or captured by the elongate sheet, and an inflatable tube attached to or captured by the elongate sheet. The bistable tape spring has a first stable state which is a straightened-out state, a second stable state which is a rolled-up state, and a transition state between the first and second stable states. The inflatable tube is sealed at one end and has an orifice at the other end for admission of a fluid therethrough for inflation of the inflatable tube.

A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.