A composite structure manufacturing method comprising: a lamination step in which a plurality of fiber-reinforced resin sheets are laminated to form a plate-shaped laminate; a pressing deformation step in which a third roller or similar, which rolls along a plate surface of the laminate, is used to press the plate surface of the laminate, thereby forming a recessed section or a protruding section in a prescribed section of the laminate; a short direction deformation step in which, after the pressing deformation step, the laminate is deformed in the short direction to make the long direction cross-section into a prescribed shape; and a long direction deformation step in which, after the pressing deformation step, the laminate is deformed in the long direction to make the short direction cross-section into a prescribed shape.

An improved shaped composite rebar is disclosed.

A stiffener 100 comprises a first stiffener portion (102), having a first cross-sectional profile (104) that is constant along the first stiffener portion (102). The stiffener 100 also comprises a second stiffener portion (106), having a second cross-sectional profile (108) that is constant along the second stiffener portion (106). The second cross-sectional profile (108) of the second stiffener portion (106) is different from the first cross-sectional profile (104) of the first stiffener portion (102). The stiffener 100 additionally comprises a transition stiffener portion (110) tapering from the second stiffener portion (106) to the first stiffener portion (102).

An example method of forming a composite structure is described that includes applying a laminated charge onto an expandable pallet, moving the expandable pallet at a translation rate and relative to a die conveyor that comprises a plurality of die sections, and driving the plurality of die sections on the die conveyor at an angle relative to the expandable pallet so as to drive the plurality of die sections progressively deeper into a recess defined by the expandable pallet and shape the laminated charge into at least part of a shape of the composite structure.

Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.

A method for manufacturing a structural element for a fuselage of an aircraft. To improve the manufacture of structural elements, a method includes laying up textile material members on a mandrel to form a plurality of structural element preforms that are space apart along an extended direction of the mandrel. The structural element preforms form closed loops and are subsequently cured to obtain annular structural elements. The annular structural elements are used as basic building blocks for stiffening panel members or are directly used as structural frame elements reinforcing cut-outs in a fuselage for windows and/or doors.

Provided are methods and devices for supporting of variety of different pre-cured composite stringers after forming and prior to curing. A post-forming processing device comprises a base with a channel for receiving hat portions of different stringers. The device also comprises a support structure, at least partially extending within the channel. The support structure is configured to conform to different hat portions and to retain the shape of these hat portions. For example, the support structure is made from a flexible material, which conforms to any shape variations. In some examples, the support structure is made from a jamming material that is reshaped together with each of the pre-cured composite stringers. A post-forming processing device is used for supporting different pre-cured composite stringers while various operations are performed on these stringers, such as stringer trimming, inspection, installation of bladders and noodles, and the like.

A forming module for forming a composite laminate part over a tool is provided. The forming module comprises a base, a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted, and a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.

Examples are disclosed herein that relate to vehicles, composite parts, and three-dimensional (3D) textile preforms for composite parts. In one example, a 3D textile preform for a composite part comprises a flange portion and a stiffener portion extending upwardly from the flange portion. The stiffener portion comprises a first wall portion that extends from the flange portion and a second wall portion that extends from the flange portion at a location spaced from the first wall portion. A connecting portion connects the first wall portion and the second wall portion at a location spaced from the flange portion.