Apparatus, method and computer readable medium for compacting objects onto a rigid tool

Abstract

This application relates to apparatuses, methods, and computer-readable media for pinching an object to a rigid tool. One embodiment is a method for pinching an object to a rigid tool. The method includes: placing the object on a surface of the rigid tool; positioning an end effector over the object; deploying links of the end effector so that a roll of material between the links is positioned on top of the object while surrounding the object; and applying negative pressure to the roll to counteract air leaks between the roll and the object, thereby forming a suction hold that pinches the object to the rigid tool.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of manufacturing and, in particular, to the preparation of composite parts. BACKGROUND

[0002] Composite parts, such as carbon fiber parts, are formed by hardening a preform of fiber-reinforced material while maintaining a desired amount of pressure and temperature. The preform, which has not yet been hardened into a composite part, does not exhibit full structural strength. As a result, a "green" preform, before being hardened, is not able to support itself when laid up onto a surface (e.g., a vertical or other non-horizontal surface). This complicates layup of large preforms onto complex surfaces (e.g., a barrel shape) because it increases the chance that portions of the preform will peel or shift from the forming tool before layup is complete. Thus, accurate placement or positioning of a layup that is large scale and / or cumbersome remains difficult.

[0003] For preforms that are hardened via vacuum bag curing techniques, it is difficult to secure a vacuum bag around the preform before the preform peels (relatively shifts) from the corresponding complex surface. Materials used to secure the vacuum bag to the tool surface, such as tape, are not approved for contact and thus are not allowed to contact uncured / unhardened composite material, which further complicates the issue. As a result, the entire layup must be completed before the vacuum bag is applied and attached to the complex surface (via a sealant). Thus, it is still desirable to quickly and efficiently secure a preform (and / or other objects) to a complex surface, particularly when the preform is being placed into a complex assembly.

[0004] Accordingly, it would be desirable to have a method and apparatus that addresses at least some of the issues described above, as well as other possible issues. SUMMARY

[0005] Embodiments described herein provide techniques in which a roll of material is quickly deployed into a preform that has been placed on a mandrel. The roll includes a permeable layer that allows airflow and an impermeable layer that extends beyond the boundaries of the permeable layer. During and after placement of the roll, negative pressure is applied via a tapeless compaction process to press the roll into and compact the underlying preform. After compaction is complete, the roll can be quickly removed to allow the preform to be vacuum bagged and hardened.

[0006] One embodiment is a method for compacting an object onto a rigid tool. The method includes placing the object onto a surface of the rigid tool; positioning an end effector over the object; deploying links of the end effector so that a roll of material between the links is positioned on top of the object while surrounding the object; and applying negative pressure to the roll to counteract air leakage between the roll and the object, thereby forming a suction hold that compacts the object onto the rigid tool.

[0007] Another embodiment is a non-transitory computer readable medium comprising programming instructions that, when executed by a processor, operate to perform a method for pressing an object onto a rigid tool. The method comprises: placing the object onto a surface of the rigid tool; positioning an end effector above the object; deploying links of the end effector such that a roll of material between the links is positioned on top of the object while encircling the object; and applying negative pressure to the roll to counter air leaks between the roll and the object, thereby forming a suction hold that presses the object onto the rigid tool.

[0008] Another embodiment is an apparatus for pressing an object onto a rigid tool. The apparatus comprises: an end effector configured to move toward the rigid tool; a link coupled to the end effector and configured to pivot relative to the end effector; a spool coupled to the link and rotatably mounted to the link; and a roll of material stored on the spool and configured for placing the object onto the rigid tool.

[0009] Another embodiment is an apparatus comprising a spool and a roll of material wound around the spool. One end of the roll is sealed to the spool, and another end of the roll is attached to an object. The material comprises a permeable layer and an impermeable membrane contacting the permeable layer.

[0010] Another embodiment is an apparatus comprising at least one spool. The spool comprises an outer portion, a cavity, and a through-hole coupling the cavity to the outer portion. The apparatus further comprises a roll of material wound around the spool. One end of the roll is sealed to the spool. The material comprises a permeable layer and an impermeable membrane contacting the permeable layer.

[0011] Another embodiment is an apparatus for pressing an object onto a rigid tool. The apparatus comprises: a plurality of spools; and a roll of material stored on the spools and configured to perform a placement on the object at the rigid tool when the spools are moved away from each other.

[0012] Another embodiment is a method of pressing an object placed on a surface of a rigid tool. The method comprises: unwinding a roll of material above the object, including an impermeable membrane covering a permeable layer and extending beyond a boundary of the permeable layer; and applying negative pressure to the permeable layer to counter air leaks between the roll and the object, thereby forming a suction hold that presses the object onto the rigid tool.

[0013] Another embodiment is a non-transitory computer readable medium comprising programming instructions operable when executed by a processor to perform a method of compacting an object onto a rigid tool. The method comprises: laying out a roll of material over the object, including an impermeable membrane that covers a permeable layer and extends beyond the boundaries of the permeable layer; and applying negative pressure to the permeable layer that counteracts air leaks between the roll and the object, thereby forming a suction hold that compacts the object onto the rigid tool.

[0014] Other illustrative embodiments (e.g., methods and computer readable media related to the above-described embodiments) can be described below. The features, functions, and advantages described herein can be implemented independently in various embodiments of the present disclosure or can be combined in some embodiments to produce additional features, functions, or advantages. Various embodiments can include additional or different features, functions, or advantages. BRIEF DESCRIPTION OF DRAWINGS

[0015] Some embodiments of the present disclosure are now described, by way of example only, and with reference to the accompanying drawings. The same reference numbers in different drawings represent the same element or the same type of element.

[0016] Figure 1 A roll deployment system in an illustrative embodiment is shown.

[0017] Figure 2 is a flowchart showing a method for operating a roll deployment system in an illustrative embodiment.

[0018] Figure 3 An end effector with an undeployed roll in an illustrative embodiment is described.

[0019] Figure 4 An end effector with a deployed roll in an illustrative embodiment is described.

[0020] Figure 5 is a cross-sectional cut view of a roll in an illustrative embodiment.

[0021] Figure 6 is a zoomed-in view of a portion of a roll including various layers of fiber-reinforced material in an illustrative embodiment.

[0022] Figure 7 A permeable layer in an illustrative embodiment is described.

[0023] Figure 8 is a diagram depicting a vacuum system coupled to a turret in an illustrative embodiment.

[0024] Figure 9 is a cross-sectional view of a turret in an illustrative embodiment. Figure 8

[0025] is a cross-sectional view of a turret in an illustrative embodiment.Figure 10 is a flowchart depicting a method of applying negative pressure via a pivot in an illustrative embodiment.

[0026] Figure 11 is a flowchart depicting a method of unwinding a roll from a single pivot in an illustrative embodiment.

[0027] Figure 12 is a flowchart of an aircraft production and service method in an illustrative embodiment.

[0028] Figure 13 is a block diagram of an aircraft in an illustrative embodiment. DETAILED DESCRIPTION

[0029] The figures and the following description provide specific illustrative embodiments of the disclosure. It is understood, however, that no limitation of the scope of the disclosure is intended by delineating the general nature of these embodiments. As such, those skilled in the art will appreciate that various adaptations and modifications of the concepts described herein can be accomplished and that the scope of the disclosure is to be construed as not limited to the particular illustrative embodiments presented in this specification. Further, any example set forth herein is intended to be illustrative and not limiting. Thus, the disclosure is not to be limited to the specific embodiments set forth below or by the exercises of the claims, and includes all alterations, further modifications, and / or the like coming within the intended purview thereof.

[0030] The roll deployment systems described herein can be used to compact preforms of composite parts, such as preforms of fuselage sections, and the like. Initially, composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are laid up in multiple layers that are collectively referred to as a preform. The individual fibers within each layer of the preform are aligned parallel to one another, but different layers exhibit different fiber orientations to enhance the strength of the composite part being synthesized along different dimensions. The preform includes a viscous resin that is cured to harden the preform into a composite part (e.g., for use in an aircraft). Carbon fibers that are impregnated with uncured thermoset resin or thermoplastic resin are referred to as "prepregs." Other types of carbon fibers include "dry fibers" that have not been impregnated with thermoset resin, but can include tackifiers or adhesives. Dry fibers are infused with resin prior to hardening. For thermoset resins, hardening is a one-way process known as curing, whereas for thermoplastic resins, the resin becomes tacky if reheated, after which it can be set into a desired shape and cured. As used herein, the encompassing term for the process of converting a preform into a final hardened shape (i.e., the preform is converted into a composite part) is referred to as "hardening," and this data encompasses both the curing of thermoset preforms and the shaping / curing of thermoplastic preforms into a final desired shape.

[0031] Figure 1A roll deployment system 100 in an illustrative embodiment is shown schematically. The roll deployment system 100 comprises any system or device that is capable of deploying a roll of material (e.g., a preform for a section of a fuselage of an aircraft set on a mandrel) on an object disposed at a rigid tool and applying a negative pressure that uniformly presses the object against the rigid tool. In the present embodiment, the roll deployment system 100 comprises an end effector 120 configured to move (downwardly toward) a rigid tool 110. A link 122 is coupled to the end effector and configured to pivot relative to the end effector. As the link 122 pivots, its distal ends 123 move away from each other. A spindle 124 is coupled to the link and rotatably mounted to the link 122. Further, the spindles 124 each store a portion of a roll 130 of continuous material configured to place an object 140 onto the rigid tool 110. In this way, the spindles 124 carry the roll 130 material. In one embodiment, the roll 130 comprises a permeable layer and an impermeable membrane, and the impermeable membrane extends beyond the perimeter of the permeable layer. In a further embodiment, the roll 130 also comprises one or more layers of fiber reinforced material for pressing onto the object 140.

[0032] Pivoting of the link 122 causes the spindles 124 to rotate to deploy the roll 130 material from the spindles 124. After deployment, the roll 130 covers the object 140 and extends beyond the boundaries of the object 140 (e.g., and circumferentially into and out of the page). Accordingly, Figure 1 The roll 130 in a deployed configuration relative to the object 140 is described. In the present embodiment, the object 140 is a preform comprising multiple layers of fiber reinforced material (e.g., CFRP), disposed at a surface 112 of the rigid tool 110, and awaiting hardening into a composite part.

[0033] During and / or after deployment of the roll 130, a pump 150 operates to draw air from beneath the roll 130. In particular, the pump 150 draws air from beneath the impermeable membrane 132 of the roll 130 (e.g., a latex sheet or other material that exhibits a high level of elongation while preserving impermeability) that covers the object 140. The pump 150 draws air via a port 152 that penetrates the roll 130 at a hole 133 by applying a negative pressure via the port 152. In the present embodiment, the port 152 is located at an upper end 182 of the roll 130. However, the port 152 can be located at other desired portions of the roll as desired. The port 152 penetrates the impermeable membrane 132 and can be in direct contact with or positioned directly above the permeable layer 134 of the roll 130.

[0034] The permeable layer 134 is air permeable in both the lateral and vertical directions to enable uniform distribution of negative pressure across the roll 130. This means that the negative pressure drawn via the ports 152 is applied uniformly on the object 140, rather than being localized at the ports 152. The negative pressure causes the end cuff 136 of the roll to be secured to the rigid tool 110 and forms a loose seal between the end cuff 136 and the rigid tool 110. That is, even if the end cuff 136 does not include adhesive or other chemical bonding means, the loose application of negative pressure causes the end cuff to be sealed to the rigid tool 110 via suction as long as the amount of air drawn by the pump 150 is at least equal to the amount of air lost through leakage between the end cuff 136 and the rigid tool 110. The negative pressure also presses the roll 130 against the object 140 to ensure that the object 140 remains in place in the rigid tool 110.

[0035] The pump 150 is a high flow pump, that is, the pump 150 is capable of drawing a large amount of air through the ports 152, rather than having to draw air at high pressure. In one embodiment, the pump 150 applies a negative pressure of between twenty-two and twenty-nine inches of mercury (in Hg units) to form a vacuum, but the air flow is in the tens of cubic feet per minute (CFM) (e.g., between fifty and two hundred CFM). Thus, the pump 150 and the ports 152 are capable of maintaining at least one inch of pressure on an impermeable membrane (e.g., a cover area). This can be performed by the pump 150 alone or in combination with other pumps as needed. The amount of pressure applied by the pump 150 and the amount of CFM drawn can vary depending on the total perimeter length of the roll 130.

[0036] The controller 160 manages the operation of the pump 150 based on input from sensors (not shown), such as pressure sensors or flow rate sensors, to ensure that the negative pressure is consistently within a desired range that overcomes air leakage along the perimeter of the roll 130. The sensors can be located at any suitable location, such as on the permeable layer 134, the roll 130, the ports 152, the pump 150, etc. In one embodiment, the controller 160 increases or decreases the speed or intensity of the pumping operation at the pump 150 to maintain a constant air flow, or to maintain a constant negative pressure. For example, the controller 160 can be implemented as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0037] The amount of holding force (F H ) applied to the object 140 by the roll 130 is based on the difference between the volume per unit time (Vp) drawn by the pump 150, the volume per unit time (V1) leaked through the end cuff 136 of the roll 130, and the total area covered by the roll 130. The F HModeling is performed. VL is overcome by VP. Therefore, VP should be equal to or greater than VL. Roll 130 is attached to rigid tool 110 without sealant, adhesive, fasteners, magnetism, etc. However, a vacuum is maintained below roll 130 by pump 150 while air leaks into the system through the perimeter. Thus, a small amount of air leakage may still exist in this configuration because negative pressure is the main (e.g., only) force holding roll 130 to rigid tool 110. Leakage may be caused by folds in the roll 130 that provide airflow channels. However, when roll 130 is not sealed to rigid tool 110, folds are only one cause of leakage because air leaks beyond the edges of roll 130. Even so, VL is still small, and therefore, negative pressure is maintained by venting an equal or greater amount of air lost through leakage between the end flaps 136 of the impermeable membrane 132 and rigid tool 110.

[0038] The permeable layer 134 comprises a material that is deformable when force is applied to the impermeable membrane 132, allowing air to be drawn freely across the object 140 while adhering to it for air intake. In other words, the permeable layer 134 can draw air across the object 140 without displacing it. For example, the permeable layer 134 may comprise a conforming double-plane mesh material that facilitates airflow. The permeable layer 134 is a highly fluid material, meaning that it does not sufficiently restrict the rate at which the pump 150 draws air. Therefore, the resistance of the permeable layer 134 to airflow has a negligible effect on the flow rate of the pump 150. In some embodiments, the permeable layer 134 comprises an open-cell foam material. However, in this embodiment, the selected open-cell foam material is stiff enough that it is not collapsed beneath the impermeable membrane 132, and open enough that airflow is not inhibited. Since the airflow from the region below the impermeable membrane 132 is subsequently restricted, the collapse of the impermeable membrane 132 will shut down or restrict the airflow, which is undesirable.

[0039] The impermeable membrane 132 may comprise any suitable, flexible, airtight material. For example, the impermeable membrane 132 may comprise a plastic sheet that prevents air from escaping directly through it. In a further embodiment, for convenience, the impermeable membrane 132 and the permeable layer 134 may be structurally bonded or adhesively connected. In one embodiment, the permeable layer 134 and the impermeable membrane 132 comprise an approved contact material that accepts the use of the bonded carbon fiber composite and does not chemically interact with the resin.

[0040] The implementation of the method (shown as) Figure 2 The method in section 200) will be discussed in illustrative detail regarding the operation of the roll deployment system 100. For this embodiment, it is assumed that the rigid tool 110 is waiting to place the preform for compression and hardening into a composite component.

[0041] Figure 2 FIG. 2 is a flowchart illustrating a method 200 for operating a volume deployment system in illustrative embodiments. Reference is made to FIG. 1 in describing the steps of method 200, but one skilled in the art will recognize that method 200 can be performed in other systems. The steps of the flowchart described herein are not all inclusive and can include other steps not shown. The steps described herein can also be performed in alternative orders. Figure 1

[0042] In step 202, an object 140 is placed onto surface 112 of rigid tool 110. In one embodiment, this includes laying up a preform onto surface 112 via an automated fiber placement (AFP) machine or other tool. In a further embodiment, this includes picking up and placing a preform from another location and placing it onto surface 112.

[0043] Step 204 includes positioning end effector 120 over object 140. In one embodiment, this includes moving end effector 120 on a rail, gantry, or track (not shown) so that end effector is aligned with object 140.

[0044] Step 206 includes unwinding links 122 of end effector 120 so that volume 130 of material between links 122 is disposed on top of object 140 while still encircling the object. In one embodiment, as end effector 120 descends, links 122 unwind due to gravity as pivot shafts 124 follow the contours of rigid tool. At the same time as unwinding, links pivot relative to end effector 120. This brings links 122 into contact with rigid tool 110 (and / or object 140) and deflects from rigid tool 110 (and / or object 140), swinging outward. In a further embodiment, links are motorized and actively driven apart from each other. As links 122 unwind, pivot shafts 124 coupled to links rotate. Because volume 130 is wound around pivot shafts 124, rotation of pivot shafts causes volume 130 to be dispensed, or causes material at volume to lay out / be disposed in place. That is, as links 122 unwind, pivot shafts 124 begin to roll in the opposite direction, exposing volume 130 for deployment. That is, because one portion of volume 130 remains at pivot shaft 124 of one link 122, and another portion of volume remains at pivot shaft of another link, the act of links unwinding causes volume 130 to lay out from pivot shafts.

[0045] ​In step 208, the roll 130 is unwound over the object 140, the roll 130 including an impermeable membrane that covers the permeable layer and extends beyond the boundaries of the permeable layer. In one embodiment, this occurs in response to the unwinding of the link, while in further embodiments in which the link is not utilized, this includes unwinding the roll 130 via any other suitable means.

[0046] In step 210, the port 152 applies negative pressure to the roll 130 to counteract air leakage between the roll 130 and the object 140, thereby forming a suction hold that presses the object 140 against the rigid tool 110. The application of negative pressure draws the end nip 136 of the impermeable membrane 132 of the roll 130 into contact with the rigid tool 110. The application of negative pressure can be performed by drawing the required volume flow through the pump 150 as described above or by applying a constant amount of pressure through the pump 150. The application of negative pressure causes air to be expelled beneath the roll 130 as air is drawn through the port 152. The negative pressure applies the required force for the required period of time to achieve full contact with the object 140.

[0047] After the pressing is complete, the link 122 retracts, thereby pulling the roll 130 upward from the preform. In embodiments in which the roll 130 includes one or more layers of fiber reinforcement material, the pressing process secures the fiber reinforcement material to the object 140. Thus, when the roll 130 is retracted, these layers of fiber reinforcement material remain at the object 140, while the permeable layer 134 and the impermeable membrane 132 are retracted. After the roll 130 is removed, the roll 130 can be cleaned, reloaded with additional layers of fiber reinforcement material, and / or replaced with another spool that has been cleaned and loaded with the required material.

[0048] The method 200 provides technical benefits over the prior art because the tapeless pressing system can be quickly deployed via an end effector that occupies relatively little space. It also enables the deployment of layers of fiber reinforcement material as part of the pressing process. This increases production speed and reduces labor.

[0049] Figure 3 An end effector 300 with an undeployed roll in a demonstrative embodiment is described. In this embodiment, the end effector 300 includes a frame 330 and a base 332 from which a link 334 extends. An actuator 336 is disposed at the link 334 and facilitates the retraction of the link 334 by rolling the spool 338 upward along the mandrel 310 after the pressing is complete. In one embodiment, the actuator 336 includes a motor with a slip clutch that moves the spool 338 upward and backward after the pressing is complete. In this embodiment, the end effector 300 deploys a roll of material from the spool 338 into a preform 320 that is placed on the mandrel 310.

[0050] Figure 4 Described Figure 3 The diagram shows the deployment volume 400 with an end effector 300 as illustrated in the embodiment. For example... Figure 4 As shown, the spindle 338 has been moved to the deployment roll 400 so that the roll 400 covers the entire preform 320. The pump 420 applies negative pressure during the deployment of the roll 400 using the vacuum port 410, and is also used to press the preform 320 into place after deployment.

[0051] Figure 5 This is a cross-sectional view of volume 400 in the illustrative embodiment and is related to... Figure 3 This corresponds to arrow 5 in the diagram. Roll 400 is wound around pivot 338, and as link 334 unfolds outward, pivots 338 roll apart. This exposes roll 500 of roll 400 for deployment.

[0052] Figure 6 It is a scaled view of a portion of a roll including the fiber-reinforced materials of each layer in the illustrative embodiment and is related to Figure 5 It corresponds to region 6 in the text. Figure 6 The roll 400 is shown to include multiple layers. In this embodiment, the roll 400 includes one or more layers 621 of fiber reinforcement material. When the roll 400 is deployed, the layers 621 are in direct contact with the object below and can form an outer mold line (OML) or inner mold line (IML) stack of the composite component. As described above, the permeable layer 614 is after the layer 612 and is able to apply a negative pressure uniformly distributed along the underside of the roll 400 during deployment. In embodiments where the roll 400 does not include individual layers of fiber reinforcement material, the permeable layer 614 is positioned to be in direct contact with the object below. An impermeable layer 616 is after the permeable layer 614 and prevents airflow from crossing when the roll is deployed. When flattened, the roll 400 includes only one group 610 of layers 612, the permeable layer 614, and the impermeable layer 616. However, the roll 400 is wound around a pivot such that the group 610 is visible multiple times along the diameter of the pivot.

[0053] Figure 7A permeable layer that is vertically and horizontally air permeable in the illustrative embodiment is described. That is, air 710 can flow freely through the gaps 720 in the permeable layer 700 and across the gaps 720 in the permeable layer 700. This is possible because the permeable layer 700 is a bi-planar mesh. The first layer 730 of the bi-planar mesh includes structural elements 732 arranged parallel to each other and the second layer 740 of the bi-planar mesh includes structural elements 742 arranged parallel to each other, but the second layer 740 is in a different direction than the first layer 730. The first layer 730 enables air to flow horizontally in a first direction and the second layer 740 enables air to flow horizontally in a second direction. At the same time, both layers allow air to flow freely in the vertical direction. Thus, if a negative pressure is applied to a portion of the permeable layer 700, the negative pressure can draw air evenly across the entire permeable layer 700. The permeable layer 700 enables air flow to be free and does not interfere with the pumping of air. That is, the permeable layer 700 does not limit the CFM rate of the pump. The permeable layer 700 can include polyethylene, polypropylene, nylon, etc. In one embodiment, the permeable layer 700 is selected as a "clean contact" material that does not chemically interact with the adhesive of the curing resin at the secured object. For example, the permeable layer 700 can be constructed of a silicone-free material that does not mar the underlying object 140.

[0054] The above-described apparatus and methods involve the use of a pair of opposing rollers and a vacuum port configured to apply a vacuum via a hole in the material. However, in other embodiments, further configurations are possible. For example, in further embodiments, the material is rolled on a single roller, rather than on a pair of opposing rollers, and / or the vacuum is applied via the end of the roller shaft, via a cavity in the shaft, and through a perforation in the shaft. To illustrate these configurations, Figures 8 to 11 Embodiments of a vacuum system including these configurations and methods utilizing the system are illustrated in FIGS. 800-850 and described below.

[0055] Figure 8 is a diagram 800 illustrating a vacuum system 870 coupled to a shaft 840 in an illustrative embodiment. As shown in FIG. 800, the shaft 840 includes a cavity 842 having a plurality of perforations 844 leading to the exterior 846. The cavity 842 is in communication with a vacuum port 850, i.e., when the vacuum system 870 expels air from the vacuum port 850, air within the cavity 842 is removed. Figure 8

[0056] A roll 838 of material 830 is wrapped around the shaft 840 and covers an underlying preform 860 for a composite part or any other suitable object. The end of the roll 838 is sealed to the shaft 840 around the perforations 844 such that suction applied via the vacuum port 850 creates a negative pressure that is evenly distributed through the roll 838. The roll 838 is described in more detail below with respect to FIG. 840. Figure 9 ​Further details of the arrangement are provided in the document.

[0057] The other end 836 of the material 830 of the roll 838 is attached to the surface 812 of the mandrel 810 via tape 820. In a further embodiment, the end 836 is attached to the mandrel 810 by applying negative pressure to the roll 838. The material 830 comprises multiple layers, including at least one impermeable membrane 832 and a permeable layer 834 (e.g., a double-planar mesh) disposed beneath the impermeable membrane 832. The permeable layer 834 is in fluid communication with a cavity 842 within the shaft 840. (Refer to below...) Figure 9 Further details of the layer arrangement of Material 830 were discussed.

[0058] The hollow shaft 840 and / or the coupling of the vacuum port 850 to the hollow portion of the shaft 840 provide multiple benefits by enabling a single component (i.e., the shaft) to perform multiple functions, facilitating not only the spreading of material but also the clamping of the underlying preform 860. In a further embodiment, multiple shafts (such as...) Figure 3 and Figure 4 The shaft described herein (e.g., the rotating shaft) is implemented as a hollow rotating shaft with a cavity and a vacuum port to apply negative pressure. In this embodiment, the vacuum ports of different rotating shafts can be provided on the same side of each rotating shaft, on different sides of the rotating shaft, or on both sides of the rotating shaft, as needed.

[0059] Figure 9 This is an illustrative implementation method. Figure 8 A cross-sectional view of the rotating shaft 840 is shown in Figure 900. Figure 9 The scale in the middle is adjusted to better show the relationship with Figure 8 The other components described herein relate to shaft 840, and therefore, the scales of these figures do not correspond. As indicated by the arrows, Figure 9 This illustrates how airflow moves from material 830 to shaft 840 when suction is applied. (As shown) Figure 9 As shown, the permeable layer 834 extends to contact and thus is in fluid communication with the perforation 844. Further, the perforation 844 is located between the end 936 of the roll and the position 938 of the shaft 840. The permeable layer 834 is defined by a first impermeable membrane 832 forming an upper boundary on the top of the preform 860 and further defined by a second impermeable membrane 910 forming a lower boundary. The impermeable membrane contacts the permeable layer and thus contains the airflow within the permeable layer 834.

[0060] The first impermeable membrane 832 terminates after the permeable layer 834, and the second impermeable membrane 910 terminates before reaching the preform 860. The second impermeable membrane 910 prevents pressure loss during and after the lay-up process by providing a direct path to the lumen 842 of the mandrel 840. In further embodiments such as discussed above, the roll 838 is wrapped around the second mandrel, and the end 836 of the roll is sealed to the second mandrel in a similar manner as described above with respect to the end 936.

[0061] Figure 10 is a flowchart illustrating a method 1000 of applying negative pressure via a mandrel in an illustrative embodiment. Step 1002 includes placing the mandrel 840 on top of an object such as a preform for a composite part. This can include physically placing the mandrel 840 on the object or the mandrel 810 on which the object has been stacked. Step 1004 includes laying up the roll 838 of material 830 from the mandrel 840 on the object, thereby covering the object with the material. In some embodiments, the act of laying up brings the permeable layer into direct contact with the object.

[0062] Step 1006 includes applying negative pressure to the permeable layer 834 in the material 830 in fluid communication with the lumen 842 within the mandrel 840. In one embodiment, the negative pressure is applied via the vacuum port 850 in fluid communication with the lumen 842 and via the plurality of perforations 844 at the mandrel 840 connecting the lumen 842 to the permeable layer 834. The negative pressure is distributed across the impermeable membrane via the permeable layer to ensure that the impermeable membrane does not "pinch off" or seal itself in response to negative pressure at an undesired location. Step 1008 includes forming a suction in response to the negative pressure that draws the impermeable membrane of the material into contact with the object. The suction is naturally formed as a result of the distribution of negative pressure across the impermeable membrane. At locations where the permeable layer 834 terminates and the impermeable membrane 832 extends, the negative pressure causes the impermeable membrane to seal itself to the underlying mandrel 810.

[0063] Figure 11 is a flowchart illustrating a method 1100 of laying up a roll from a single mandrel in an illustrative embodiment. The method 1100 includes placing the mandrel 840 on top of an object at a mandrel 810 in step 1102. Step 1104 includes attaching an end 836 of a roll 838 of material at the mandrel 840 to the mandrel 810. In one embodiment, attaching the end 836 of the roll includes tacking the end 836 of the roll 838 to the mandrel 810. As described above with respect to the method 1000, in further embodiments, attaching the end of the roll includes forming a suction between the impermeable membrane of the material and the mandrel. Thus, activating the vacuum system 870 can be used to attach the end 836 as long as there is substantially no air leak.

[0064] Step 1106 includes applying negative pressure to the permeable layer in the material, thereby forming a suction hold that places the material in contact with the object. This can be performed in a manner similar to step 1008 in method 1000 discussed above. In one embodiment, the application of negative pressure is performed via the plurality of perforations 844 at the spindle that connect the cavity of the spindle to the permeable layer. The permeable layer 834 distributes the negative pressure across the impermeable membrane of the material.

[0065] Step 1108 includes unwinding the roll while the negative pressure is applied. In one embodiment, unwinding the roll includes draping a preform for a composite part. Unwinding the roll places the permeable layer in direct contact with the object. Further, because the end 836 of the roll 838 is attached in place, the roll does not kink or change position as the placement process continues. This allows the entire roll (the entire object being draped) to be unwound as desired. In a further embodiment, the method further includes compacting the object via the suction hold. This can include increasing the negative pressure until the object is fixedly pressed into the mandrel at a desired level of pressure.

[0066] Although Figures 8 to 11 A single roll, vacuum device that applies a tube, and related methods are described, in further embodiments, various aspects and features described herein are applied to various systems. For example, the Figures 8 to 11 arrangement of cavities and vacuum systems described in Figure 1 and Figures 3 to 5 two-roll embodiments described in Figures 8 to 11 may be applied via one or more ends of one or both spindles. Figure 1 and Figures 3 to 5 single-roll embodiments described in

[0067] Example

[0068] In the following embodiments, additional processes, systems, and methods are described in the context of a roll deployment system for compacting a preform onto a rigid tool (e.g., a mandrel).

[0069] More specifically, with reference to the figures, the method 1200 shown in Figure 12 is similar to Figure 9Embodiments of the disclosure are described in the context of aircraft manufacturing and service method 1200 of an aircraft 1202 as shown in FIG. 12. During pre-production, aircraft 1202 can comprise specification and design 1204 and material procurement 1206. During production, component and subassembly manufacturing 1208 and system integration 1210 of aircraft 1202 takes place. Thereafter, aircraft 1202 can go through certification and delivery 1212 to be placed in service 1214. While in service by a customer, aircraft 1202 is scheduled for routine maintenance and service 1216, which can also include modification, reconfiguration, refurbishment, and / or the like. Each of the processes of method 1200 can be performed or carried out by a

[0070] Various processes of method 1200 can be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator can include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party can include without limitation any number of retailers, subcontractors, and suppliers; and an operator can be an airline, leasee, military entity, service organization, or the like.

[0071] As Figure 13 As shown in FIG. 12, aircraft 1202 produced by processes 1200 can include airframe 1218 with plurality of systems 1220 and interior 1222. Examples of systems 1220 include one or more of propulsion system 1224, electrical system 1226, hydraulic system 1228, and environmental system 1230. Any number of other systems can be included. While an aerospace example is shown, the principles of the application can be applied to other industries, such as the automotive industry, and / or other industries.

[0072] As already mentioned above, the devices and methods encompassed herein can be employed during any one or more of the stages of production and maintenance described in the method 1200. For example, the components or subassemblies corresponding to the component and subassembly manufacturing 1208 can be prepared or manufactured in a manner similar to the components or subassemblies produced when the aircraft 1202 is initially placed in service. Moreover, for example, in the course of the subassembly manufacturing 1208 and the system integration 1210, one or more device embodiments, method embodiments, or a combination thereof, can be utilized to expedite the assembly or to reduce the cost of the aircraft 1202. Likewise, one or more device embodiments, method embodiments, or a combination thereof, can be utilized, for example and without limitation, in the course of the maintenance and service 1216 when the aircraft 1202 is in service. Thus, the present application can be employed at any stage or any combination of stages discussed herein, such as the specification and design 1204 of the aircraft 1202, the procurement of materials 1206, the component and subassembly manufacturing 1208, the system integration 1210, the certification and delivery 1212, the operation 1214, the maintenance and service 1216, and / or any suitable components or the like (e.g., the fuselage 1218, the systems 1220, the interior 1222, the propulsion system 1224, the electrical system 1226, the hydraulic system 1228, and / or the environmental system 1230).

[0073] In one embodiment, the component part comprises a portion of the fuselage 1218 and is manufactured during the component and subassembly manufacturing 1208. The component part can then be assembled into the aircraft during the system integration 1210 and then placed in service 1214 until wear renders the component part non-reusable. Thus, during the maintenance and service 1216, the component part can be discarded and replaced with a newly manufactured component part. Throughout the component and subassembly manufacturing 1208, the inventive components and methods can be utilized to manufacture the new component part.

[0074] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, processor- implemented software, processor-implemented firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. A dedicated hardware element can be referred to as a "processor," "controller," or some similar terminology, when such is provided by a single dedicated hardware component. When provided by a processor, the functions can be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which can be shared. Moreover, explicit use of the term "processor" or "controller" should not be construed to refer exclusively to hardware capable of executing software, and can implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), or other circuitry, field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), nonvolatile storage, logic or some other physical hardware component or module.

[0075] Further, the control elements can be implemented as instructions for execution by a processor or computer to perform the functions of the elements. Some embodiments of the instructions are software, program code, and firmware. When executed by the processor, the instructions are operable to direct the processor to perform the functions of the elements. The instructions can be stored on a storage device readable by the processor. Some embodiments of the storage device are digital or solid state memory, magnetic storage media such as a magnetic disk or tape, hard drive, or optically readable digital data storage media.

[0076] The present disclosure includes example implementations according to the following clauses:

[0077] Clause 1. A method for compacting an object placed on a surface of a rigid tool, the method comprising:

[0078] spreading a roll of material (208) over the object, including an impermeable membrane that covers the permeable layer and extends beyond the boundaries of the permeable layer; and

[0079] applying negative pressure to the permeable layer that counteracts air leaks between the roll and the object, thereby forming a suction hold that compacts the object onto the rigid tool (210).

[0080] Clause 2. The method of clause 1, further comprising:

[0081] positioning an end effector above the object (204); and

[0082] deploying the links of the end effector so that the roll of material is positioned on top of the object while surrounding the object (206).

[0083] Clause 3. The method of clause 2, wherein:

[0084] Applying negative pressure includes applying negative pressure through a hole in the material.

[0085] Paragraph 4. The method of any of paragraphs 2 or 3, wherein:

[0086] Applying negative pressure includes applying negative pressure to a permeable layer in the material, wherein the permeable layer is in fluid communication with a cavity within a shaft of the roll.

[0087] Paragraph 5. The method of any of paragraphs 2-4, wherein:

[0088] Unfolding the linkage of the end effector causes the shaft of the roll, which is coupled to the linkage and stores the roll, to rotate, thereby causing the roll to be dispensed.

[0089] Paragraph 6. The method of any of paragraphs 2-5, further comprising:

[0090] Causing the linkage to contract after the pinching, thereby causing the roll to be pulled upward from the object.

[0091] Paragraph 7. The method of any of paragraphs 2-6, wherein:

[0092] Unfolding the linkage of the end effector is performed by driving the end effector toward the rigid tool.

[0093] Paragraph 8. The method of any of paragraphs 2-7, wherein:

[0094] Unfolding the linkage of the end effector includes pivoting the linkage relative to the end effector.

[0095] Paragraph 9. The method of any of paragraphs 1-8, wherein:

[0096] Applying negative pressure includes expelling air from beneath the roll.

[0097] Paragraph 10. The method of any of paragraphs 1-9, wherein:

[0098] Applying negative pressure causes a flap of an impermeable membrane of the roll of material to contact the rigid tool.

[0099] Paragraph 11. The method of any of paragraphs 1-10, further comprising:

[0100] Prior to unwinding, the shaft of the roll of the material is disposed on top of the object;

[0101] wherein applying negative pressure includes applying negative pressure to a permeable layer in the material that is in fluid communication with a cavity within the shaft.

[0102] Clause 12. The method of any of clauses 1-11, wherein:

[0103] Applying the negative pressure is performed via a plurality of perforations at the spindle where the cavity of the spindle is connected to the permeable layer.

[0104] Clause 13. The method of clause 12, wherein:

[0105] Applying the negative pressure is performed via a vacuum port in fluid communication with the cavity.

[0106] Clause 14. The method of any of clauses 1-13, further comprising:

[0107] Distributing the negative pressure across the impermeable membrane via the permeable layer.

[0108] Clause 15. The method of any of clauses 1-14, wherein:

[0109] Spreading out the roll of material includes: covering a preform for a composite part.

[0110] Clause 16. The method of any of clauses 1-15, further comprising:

[0111] Compactifying the object via suction.

[0112] Clause 17. The method of any of clauses 1-16, further comprising:

[0113] Placing the permeable layer in direct contact with the object during the spreading out.

[0114] Clause 18. The method of any of clauses 1-17, further comprising:

[0115] Attaching an end of the roll of material to a rigid tool.

[0116] Clause 19. The method of clause 18, wherein:

[0117] Attaching the end of the roll includes: conforming the end of the roll to the rigid tool.

[0118] Clause 20. A non-transitory computer readable medium comprising programmatic instructions that, when executed by a processor, operate to perform a method for compactifying an object placed on a surface of a rigid tool, the method comprising:

[0119] Spreading out a roll of material (208) over the object includes: covering a permeable layer and extending an impermeable membrane beyond a boundary of the permeable layer; and

[0120] A negative pressure is applied to the permeable layer between the roll and the object, thereby forming a suction that presses the object against the rigid tool (210).

[0121] Clause 21. The medium of clause 20, wherein the method further comprises:

[0122] positioning an end effector above the object (204); and

[0123] unfolding a linkage of the end effector, thereby causing the roll of material to be positioned on top of the object while surrounding the object (206).

[0124] Clause 22. The medium of clause 21, wherein:

[0125] applying the negative pressure comprises applying the negative pressure through a hole in the material.

[0126] Clause 23. The medium of clause 21 or 22, wherein:

[0127] applying the negative pressure comprises applying the negative pressure to a permeable layer in the material, wherein the permeable layer is in fluid communication with a cavity within a shaft that carries the roll.

[0128] Clause 24. The medium of any of clauses 21-23, wherein:

[0129] unfolding the linkage of the end effector causes a shaft that is coupled to the linkage and that stores the roll to rotate, thereby causing the roll to be dispensed.

[0130] Clause 25. The medium of any of clauses 21-24, wherein the method further comprises:

[0131] causing the linkage to retract after the pressing, thereby causing the roll to be pulled upward from the object.

[0132] Clause 26. The medium of any of clauses 21-25, wherein:

[0133] the unfolding of the linkage is performed by driving the end effector toward the rigid tool.

[0134] Clause 27. The medium of any of clauses 21-26, wherein:

[0135] unfolding the linkage of the end effector comprises pivoting the linkage relative to the end effector.

[0136] Clause 28. The medium of any of clauses 20-27, wherein:

[0137] applying the negative pressure comprises expelling air from beneath the roll.

[0138] Clause 29. The medium of any of clauses 20-28, wherein:

[0139] Applying negative pressure causes a flap of the impermeable membrane of the roll of material to contact the rigid tool.

[0140] Clause 30. The medium of any of clauses 20-29, wherein the method further comprises:

[0141] Prior to unwinding, a spindle that is to be rolled with the roll of material is disposed on top of the object;

[0142] wherein applying negative pressure comprises applying negative pressure to the permeable layer in the material in fluid communication with a cavity within the spindle.

[0143] Clause 31. The medium of any of clauses 20-30, wherein:

[0144] Applying negative pressure is performed via a plurality of perforations at the spindle where the cavity of the spindle is connected to the permeable layer.

[0145] Clause 32. The medium of any of clauses 20-31, wherein:

[0146] Applying negative pressure is performed via a vacuum port in fluid communication with the cavity.

[0147] Clause 33. The medium of any of clauses 20-32, wherein the method further comprises:

[0148] Distributing negative pressure across the impermeable membrane via the permeable layer.

[0149] Clause 34. The medium of any of clauses 20-33, wherein:

[0150] Unwinding the roll of material comprises: covering a preform for a composite part.

[0151] Clause 35. The medium of any of clauses 20-34, wherein the method further comprises:

[0152] Constricting the object via suction.

[0153] Clause 36. The medium of any of clauses 20-35, wherein the method further comprises:

[0154] Placing the permeable layer in direct contact with the object during unwinding.

[0155] Clause 37. An apparatus for constricting an object to a rigid tool, the apparatus comprising:

[0156] a plurality of spindles (124); and

[0157] a roll (130) of material (830) stored on the spool and configured to perform a placement on the object (140) at the rigid tool (110) when the spools are moved away from each other.

[0158] Clause 38. The apparatus of clause 37, further comprising:

[0159] an end effector (120) configured to move toward the rigid tool; and

[0160] a link (122) coupled to the end effector and configured to pivot relative to the end effector;

[0161] wherein the spool is coupled to the link and rotationally mounted to the link.

[0162] Clause 39. The apparatus of clause 37 or clause 38, wherein:

[0163] the roll includes a permeable layer (134) and an impermeable membrane (132); and

[0164] the impermeable membrane extends beyond a perimeter of the permeable layer.

[0165] Clause 40. The apparatus of any one of clauses 37-39, wherein:

[0166] the rigid tool includes a mandrel (310) for a section of a fuselage of an aircraft.

[0167] Clause 41. The apparatus of any one of clauses 37-40, further comprising:

[0168] a port (850) penetrating into the roll; and

[0169] a pump (150) to apply negative pressure via the port.

[0170] Clause 42. The apparatus of any one of clauses 37-41, wherein:

[0171] the roll extends beyond the object.

[0172] Clause 43. The apparatus of any one of clauses 37-42, wherein:

[0173] the roll includes at least one layer of fiber-reinforced material.

[0174] Clause 44. An apparatus comprising:

[0175] at least one spool (124) further comprising:

[0176] an outer portion (846);

[0177] a cavity (842); and

[0178] a perforation (844) coupling the cavity to the exterior; and

[0179] a roll (838) of material (830) wound about the spindle, wherein an end (836) of the roll is sealed to the spindle, and wherein the material comprises:

[0180] a permeable layer (834); and

[0181] an impermeable membrane (832) in contact with the permeable layer.

[0182] Clause 45. The apparatus of Clause 44, wherein:

[0183] the cavity is coupled to a vacuum system (870).

[0184] Clause 46. The apparatus of Clause 45, further comprising:

[0185] a vacuum port (850) in fluid communication with the cavity at the spindle that couples the spindle to the vacuum system.

[0186] Clause 47. The apparatus of any one of Clauses 44-46, wherein:

[0187] the permeable layer comprises a biplanar mesh.

[0188] Clause 48. The apparatus of any one of Clauses 44-47, wherein:

[0189] the material further comprises a second impermeable membrane (910) in contact with the permeable layer.

[0190] Clause 49. The apparatus of any one of Clauses 44-48, wherein:

[0191] the at least one spindle comprises two spindles, wherein the roll is wound about each of the two spindles, and the end (836) of the roll is sealed to the two spindles.

[0192] Clause 50. The apparatus of any one of Clauses 44-49, wherein:

[0193] a preform is disposed between the locations where the end of the roll is sealed to the spindle.

[0194] Clause 51. A method comprising:

[0195] disposing a spindle on top of an object located at a mandrel (1102).

[0196] attaching an end of the roll of material at the spindle to the mandrel (1104);

[0197] applying negative pressure to the permeable layer in the material, thereby forming a suction hold that places the material in contact with the object (1106); and

[0198] spreading the roll while applying the negative pressure (1108).

[0199] Clause 52. The method of clause 51, wherein:

[0200] attaching the end of the roll comprises conforming the end of the roll to the mandrel.

[0201] Clause 53. The method of clause 51 or clause 52, wherein:

[0202] attaching the end of the roll comprises forming a suction hold between the impermeable membrane of the material and the mandrel.

[0203] Clause 54. The method of any of clauses 51-53, wherein:

[0204] applying the negative pressure is performed via a plurality of perforations at the spindle that connect the cavity of the spindle to the permeable layer.

[0205] Clause 55. The method of any of clauses 51-54, wherein:

[0206] spreading the roll comprises draping a preform for a composite part.

[0207] Clause 56. The method of any of clauses 51-55, further comprising:

[0208] compressing the object via the suction hold.

[0209] Clause 57. The method of any of clauses 51-56, further comprising:

[0210] distributing the negative pressure across the impermeable membrane via the permeable layer.

[0211] Clause 58. The method of any of clauses 51-57, further comprising:

[0212] placing the permeable layer in direct contact with the object during the spreading.

[0213] While specific embodiments are described herein, the scope of the disclosure is not limited to these specific embodiments. The scope of the disclosure is defined by the following technical solutions and their equivalents.

Claims

1. A method for drape pressing an object placed on a surface of a rigid tool, the method comprising: spreading a roll of material over an object by a spindle, the roll of material comprising a permeable layer, an impermeable membrane covering the permeable layer and extending beyond the boundaries of the permeable layer, and an impermeable layer below the permeable layer, wherein the spreading step further comprises: positioning an end effector above the object; and unfolding a linkage of the end effector, thereby positioning the roll of material on top of the object while surrounding the object; and applying a negative pressure to a cavity within the spindle, wherein the cavity is in fluid communication with the permeable layer, wherein the negative pressure in the permeable layer counteracts air leakage between the roll of material and the object, thereby forming a suction hold that drape presses the object onto the rigid tool.

2. The method of claim 1, wherein: unfolding the linkage of the end effector causes a spindle coupled with the linkage and storing the roll of material to rotate, thereby causing the roll of material to be dispensed.

3. The method of claim 1, wherein: applying the negative pressure comprises: expelling air from below the roll of material.

4. The method of claim 1, further comprising: prior to spreading, positioning a spindle storing the roll of material on top of the object.

5. The method of claim 1, wherein: spreading the roll of material comprises: covering a preform of a composite part.

6. The method of claim 1, further comprising: drape pressing the object via the suction hold.

7. The method of claim 1, further comprising: attaching an end of the roll of material to the rigid tool.

8. A non-transitory computer readable medium comprising programming instructions that, when executed by a processor, operate to perform a method for drape pressing an object placed on a surface of a rigid tool, the method comprising: spreading a roll of material over an object by a spindle, the roll of material comprising a permeable layer, an impermeable membrane covering the permeable layer and extending beyond the boundaries of the permeable layer, and an impermeable layer below the permeable layer, wherein the spreading step further comprises: positioning an end effector above the object; and unfolding a linkage of the end effector, thereby positioning the roll of material on top of the object while surrounding the object; and applying a negative pressure to a cavity within the spindle, wherein the cavity is in fluid communication with the permeable layer, wherein the negative pressure in the permeable layer counteracts air leakage between the roll of material and the object, thereby forming a suction hold that drape presses the object onto the rigid tool.

9. An apparatus for drape pressing an object onto a rigid tool, the apparatus comprising: a plurality of spindles, wherein at least one spindle of the plurality of spindles has a cavity within the at least one spindle, the cavity configured to receive a negative pressure; and a negative pressure source in fluid communication with the cavity of the at least one spindle. a roll of material stored on the spool and configured to perform placement on an object at a rigid tool when the spools are moved away from each other, the roll of material comprising a permeable layer, an impermeable membrane covering the permeable layer and extending beyond the boundaries of the permeable layer, and an impermeable layer beneath the permeable layer, wherein the cavity is in fluid communication with the permeable layer, wherein a negative pressure communicated to the permeable layer counteracts air leakage between the roll of material and the object, thereby forming a suction hold that presses the object onto the rigid tool.

10. The apparatus of claim 9, further comprising: an end effector configured to move toward the rigid tool; and a linkage coupled to the end effector and configured to pivot relative to the end effector; wherein the spool is coupled to the linkage and rotationally mounted to the linkage.

11. The apparatus of claim 9, wherein: the rigid tool comprises a mandrel for a section of a fuselage of an aircraft.

12. The apparatus of claim 9, wherein: the roll of material extends beyond the object.

13. The apparatus of claim 9, wherein: the roll of material comprises at least one layer of fiber reinforced material.

14. An apparatus for pressing an object onto a rigid tool, comprising: at least one spool, further comprising: an exterior; a cavity within the at least one spool, the cavity configured to receive a negative pressure; and a perforation coupling the cavity to the exterior; and a roll of material wound around the spool, wherein one end of the roll of material is sealed to the spool, and wherein the material comprises: a permeable layer; an impermeable membrane covering the permeable layer and extending beyond the boundaries of the permeable layer; and an impermeable layer beneath the permeable layer, wherein the cavity is in fluid communication with the permeable layer, wherein a negative pressure communicated to the permeable layer counteracts air leakage between the roll of material and the object, thereby forming a suction hold that presses the object onto the rigid tool.

15. A method for pressing an object onto a rigid tool, comprising: positioning a spool on top of an object at a mandrel, wherein a roll of material is wound around the spool, and wherein the roll of material comprises a permeable layer covered by an impermeable membrane and an impermeable layer beneath the permeable layer; attaching a first end of the roll of material to the mandrel, wherein an opposite end of the roll of material is attached to the spool in a region of the spool that is in fluid communication with the permeable layer of the roll of material; applying a negative pressure to a cavity in the spool, wherein the cavity is in fluid communication with the permeable layer, wherein the negative pressure in the permeable layer counteracts air leakage between the roll of material and the object, thereby forming a suction hold that places the material in contact with the object; and unwinding the roll of material by rotating the spool while applying the negative pressure. ​

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