A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

A method for bending a flexible panel includes first, providing an airbag assembly; second, inflating the airbag assembly; next, abutting against the bending area with the airbag assembly; and lastly, bending the flexible panel by pivoting on the airbag assembly so that a bent portion of the flexible panel tightly contacts a surface of the airbag assembly, and the terminal area is located behind the flexible panel. The airbag assembly includes a housing and an elastic film. The housing includes at least one outlet and at least one inlet. The elastic film wraps the housing to form a gas chamber. The outlet and the inlet communicate with the gas chamber.

A drape forming apparatus includes a forming tool having a first forming surface and a second forming surface nonplanar with the first forming surface. A tray is spaced apart from the forming tool and is configured to pivot about a hinged end from a first position to a second position under an applied force such that a distal end moves away from the forming tool. A first side of the tray faces a first heat source when the tray is in the first position, and a second heat source is disposed at a second side of the tray. A device for use in forming the composite structure includes a standoff and the tray, and a heat source is secured to the second side of the tray. A method of forming a composite structure includes heating both sides of the composite material with the first and second heat sources.

A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

Disclosed herein is an apparatus for adjusting membrane height for hot drape forming. The apparatus includes a frame including an enclosable interior space and sidewalls defining a perimeter of the interior space. The apparatus further includes an adjustable collar within the interior space of the frame. The adjustable collar extends about the perimeter of the interior space and is configured to move translationally within the interior space of the frame along the sidewalls in a first direction. The apparatus further includes a membrane extending across the interior space in a second direction, perpendicular to the first direction, and co-movably coupled with the adjustable collar, wherein a position of the membrane within the interior space is adjustable in the first direction as the adjustable collar moves translationally within the interior space.

A method and apparatus includes a component having at least one opening defined by an edge and a layer of material positioned along the edge. An expandable member is positionable within a tool and is configured to operate between a non-expanded position and an expanded position in which the expandable member forces the layer of material to be folded over the edge.

A drape forming apparatus for use in forming a composite structure. The apparatus includes a forming tool including an upper forming surface and at least one side forming surface that extends from the upper forming surface. The forming tool receives at least one layer of composite material over the upper forming surface. The apparatus also includes a flange forming device including a tray coplanarly aligned with the upper forming surface when in a first operating position. The tray is configured to receive a flange portion of the at least one layer of composite material. A pressurized bladder extends over the forming tool and the tray. The pressurized bladder is configured to induce a first force against the tray such that the tray rotates about a pivot line, and such that the flange portion is withdrawn from the tray and draped over the at least one side forming surface.

A method for bending a flexible panel includes first, providing an airbag assembly; second, inflating the airbag assembly; next, abutting against the bending area with the airbag assembly; and lastly, bending the flexible panel by pivoting on the airbag assembly so that a bent portion of the flexible panel tightly contacts a surface of the airbag assembly, and the terminal area is located behind the flexible panel. The airbag assembly includes a housing and an elastic film. The housing includes at least one outlet and at least one inlet. The elastic film wraps the housing to form a gas chamber. The outlet and the inlet communicate with the gas chamber.

A drape forming apparatus for that includes a forming tool including an upper forming surface and a side forming surface extending from the upper forming surface. The forming tool receives a layer of composite material over the upper forming surface. The apparatus includes a flange forming device including an upper plate, a lower plate, and a receiving slot defined therebetween. The receiving slot receives a flange portion of the layer of composite material, and the flange forming device is translatable relative to the forming tool such that the flange portion of the layer of composite material is withdrawn from the receiving slot and draped over the side forming surface. The apparatus includes a pressurized bladder that extends over the forming tool and the upper plate. The pressurized bladder forces the flange portion against the side forming surface as the flange forming device translates relative to the forming tool.

Disclosed herein is an apparatus for adjusting membrane height for hot drape forming. The apparatus includes a frame including an enclosable interior space and sidewalls defining a perimeter of the interior space. The apparatus further includes an adjustable collar within the interior space of the frame. The adjustable collar extends about the perimeter of the interior space and is configured to move translationally within the interior space of the frame along the sidewalls in a first direction. The apparatus further includes a membrane extending across the interior space in a second direction, perpendicular to the first direction, and co-movably coupled with the adjustable collar, wherein a position of the membrane within the interior space is adjustable in the first direction as the adjustable collar moves translationally within the interior space.