A composite structure including a multi-layer laminate having a plurality of regions each oriented out of plane relative to an adjacent region, and each extending in a longitudinal dimension of the multi-layer laminate, wherein the multi-layer laminate includes at least one ply layer having an oblique fiber orientation relative to the longitudinal dimension, and wherein the at least one ply layer includes a first section and a second section each having a side edge, the first and second sections aligned side-by-side such that a first interface defined between the respective side edges is oriented to extend in the longitudinal dimension.

A window frame system, comprising a window frame having an aperture there-through and circumferentially arranged window frame through-holes in a first window frame portion and a second window frame portion, and a stringer coupling with stringer coupling through-holes in a first stringer coupling portion and a second stringer coupling portion. In an overlapping arrangement, the first window frame portion and the first stringer coupling portion are adapted to overlap with their through-holes coaxially, wherein the respective through-holes of the two first portions have different diameters.

A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

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 system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

A joint structure includes a reinforcement portion that is formed by joining a composite material and a reinforcing material through an adhesive. The composite material includes a plate portion that is formed by laminating a plurality of fiber sheets, and a raised portion that is formed by laminating a plurality of fiber sheets in addition to the plurality of fiber sheets of the plate portion, and surfaces of the plate portion and the raised portion are covered with a single fiber sheet. The reinforcement portion includes the raised portion and the reinforcing material that is bonded to the raised portion through an adhesive. A first boundary between the plate portion and the raised portion and a second boundary between the raised portion and the reinforcing material are located at different positions in an in-plane direction of a laminated interface between the fiber sheets that are laminated.

A method for the assembly of frames in an aircraft shell, wherein the aircraft shell comprises a skin and a plurality of stringers co-cured with the skin, wherein the skin has a plurality of reference marks. Identifying the reference marks on the skin using a first robot with artificial vision, establishing a local reference for the positioning of each frame based on a reference mark, grabbing a frame using the first robot, establishing a relative position between the first robot and the frame based on the reference mark, positioning the frame on an inner side of the aircraft shell using the first robot, and with a second robot, drilling holes through the frame and skin, and attaching the frame to the skin with fasteners.

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.

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 fuselage structure for an aircraft has a frame structure, which extends in a circumferential direction and has a first connecting section and a second connecting section, which is arranged spaced apart from the first connecting section, a reinforcing structure, which extends between the first and the second connecting sections and is connected respectively to the first and the second connecting sections, an outer shell, which is secured on an outer side of the reinforcing structure, and an inner shell, which is secured on an inner side of the reinforcing structure. The reinforcing structure has a profiled cross section when viewed in a longitudinal direction extending transversely to the circumferential direction and, together with the inner shell and the outer shell, forms a plurality of channels, which are adjacent to one another in the circumferential direction and each extend in the longitudinal direction.