In-line autoclave adapted to preform geometry

Abstract

To provide a method, an apparatus and a system for solidifying a preform into a composite part.SOLUTION: A method of aligning a lay-up mandrel 120 holding a preform 170 for insertion into an autoclave 180 includes: aligning the lay-up mandrel having an inner surface that complements a contour of the preform by the autoclave; and sealing the lay-up mandrel in the autoclave.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to the field of processing airframe or other highly functional components, and in particular to autoclaving such components. [Background technology]

[0002] In manufacturing airframes or other high-performance components made from composite materials (e.g., carbon fiber reinforced plastics (CFRP)), autoclaves are utilized to solidify unconsolidated preforms into finished parts. Autoclaves are designed to process composite components at high temperatures or pressures and are heated by pumping heated gases under pressure into the autoclave. In a traditional factory environment, the autoclave itself may be designed to accommodate a wide range of component geometries or multiple components in the same processing cycle. This can result in large autoclaves, which require a significant initial capital investment due to expensive construction, installation, and auxiliary equipment costs.

[0003] Larger autoclaves, due to their large thermal mass and volume to accommodate a wide variety of component geometries, require large amounts of energy and gas usage, impacting the utility costs of running the autoclave; require long times and significant energy to heat the autoclave and pump heated gas into the autoclave; and further increase operating costs because additional heated gas must be pumped, maintained, or replenished until the autoclave and its contents reach the desired processing temperature and processing time.

[0004] Large autoclaves can hinder efficient assembly line flows within a factory environment, given that they are built on dedicated bases and require gas storage tanks (e.g., for inert nitrogen) that must be located on the exterior wall. Furthermore, due to the large size, cost, and operating costs of autoclaves, it is standard for autoclaves to be used as the end point of all pre-solidification manufacturing processes in a centralized location. The transfer of components to and from the autoclave may not allow for optimal processing of components in a continuous or moving line manufacturing configuration. Furthermore, the inherent time required to heat, pressurize, and cool such autoclaves hinders efficient processing times and factory processes.

[0005] It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems.

[0006] The abstract of WO 2021 / 032430 A1 states: "The present invention relates to a method and device for producing a component from a fiber composite material (2). The method includes the steps of: introducing multiple layers (10, 11) of fibers impregnated with a matrix into a molding space (9) formed between an inner mold (3) and an outer mold (4) in an interior (3); placing a membrane (6) that seals the outer mold on the matrix-impregnated fibers so that a cavity (7) extending along the side of the outer mold is formed between the outer mold (4) and the membrane (6); and exposing the cavity (7) to a temperature-controllable pressure at a temperature higher than the melting point of the matrix and at a pressure higher than ambient pressure, thereby applying a temperature-controllable pressure fluid to the membrane together with pressure." To produce a component with at least one reinforcing layer having a particularly smooth and step-free surface, it is proposed to locally arrange at least one reinforcing layer (11) with low elongation and with fibers aligned approximately parallel on a part of the side of the base layer (10) facing the outer mold (4). A membrane (6) with an average roughness depth of less than 1.0 μm, preferably less than 0.1 μm, then applies a set pressure to the component (2) in the cavity.

[0007] The abstract of US Pat. No. 4,997,511 A states: "A method and apparatus for mass-producing composite products includes a novel autoclave having a cylindrical vacuum chamber, a cylindrical compression chamber surrounding the vacuum chamber, a reusable flexible diaphragm defining a boundary between the chambers, and means for supplying heat and pressure between the diaphragm and the compression chamber. A core or mandrel is encased in fiber-reinforced resin and placed in the autoclave within the flexible diaphragm, or the part layup can be sandwiched between an elastic cowl and a rigid tool by wrapping it with consumable shrink tape that accommodates a wide variety of part shapes, each having a constant or nearly constant cross-section along its length. The autoclave is then sealed and evacuated, causing the diaphragm to compress the resin layer against the core or mandrel due to atmospheric or elevated pressure in the compression chamber. The autoclave is then heated to cure the resin." The autoclave is then unsealed and the finished product removed, immediately making the autoclave ready for reuse. Summary of the Invention

[0008] Embodiments described herein provide an autoclave that accepts preforms that have already been laid up as part of a continuous line manufacturing process. The autoclave is sized to accept a particular type of preform and to include an interior surface that corresponds to the contour defined by the preform. This reduces the amount of volume and mass to be heated within the autoclave, thereby reducing cycle time and improving efficiency, which is a technical advantage. Additionally, the autoclaves described herein may allow consolidated composite parts to continuously exit the autoclave in the same direction they entered, thereby saving space and reducing costs on the factory floor.

[0009] Other exemplary embodiments (e.g., methods and computer-readable media related to the above-described embodiments) may also be described below. The above-described features, functions, and advantages may be realized individually in various embodiments or may be combined in yet further embodiments, further details of which can be seen with reference to the following description and drawings.

[0010] Some embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals represent the same or similar elements in all the drawings, and in which: [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a block diagram of a line assembly system including an autoclave in an exemplary embodiment. [Figure 2] FIG. 1 is a flow diagram illustrating a method for operating a line assembly system to consolidate preforms in an autoclave in an exemplary embodiment. [Figure 3] FIG. 2 is a perspective view of a preform being inserted into an autoclave in an exemplary embodiment. [Figure 4] FIG. 1 is a perspective view of an autoclave with a lay-up mandrel inserted in an exemplary embodiment. [Figure 5A] FIG. 5 is a diagram of the autoclave of FIG. 4 in an exemplary embodiment. [Figure 5B] FIG. 5 is a diagram of the autoclave of FIG. 4 in an exemplary embodiment. [Figure 5C] FIG. 5 is a diagram of the autoclave of FIG. 4 in an exemplary embodiment. [Figure 5D] FIG. 10 is an illustration of a further layup mandrel and autoclave for a wing panel in an illustrative embodiment; [Figure 5E] 1 illustrates various sealing schemes for an autoclave in an exemplary embodiment. [Figure 6]FIG. 1 is a side view of a layup mandrel including an extended area for sealing against an autoclave in an exemplary embodiment. [Figure 7] FIG. 2 is a top view of an autoclave and preparation station in an exemplary embodiment. [Figure 8] FIG. 10 is a flow diagram illustrating a further technique for operating a lay-up mandrel and a complementary autoclave in an exemplary embodiment. [Figure 9] FIG. 10 is a flow diagram illustrating a further technique for operating a lay-up mandrel and a complementary autoclave in an exemplary embodiment. [Figure 10] FIG. 10 is a flow diagram illustrating a further technique for operating a lay-up mandrel and a complementary autoclave in an exemplary embodiment. [Figure 11] FIG. 10 is a flow diagram illustrating a further technique for operating a lay-up mandrel and a complementary autoclave in an exemplary embodiment. [Figure 12] FIG. 10 is a flow diagram illustrating a further technique for operating a lay-up mandrel and a complementary autoclave in an exemplary embodiment. [Figure 13] 13 illustrates a method 1300 for moving preforms out of a clean room in an exemplary embodiment. [Figure 14] FIG. 1 is an illustration of an aircraft manufacturing and service method flowchart in an illustrative embodiment. [Figure 15] FIG. 1 is an illustration of a block diagram of an aircraft in an illustrative embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] The figures and the following description provide specific and exemplary embodiments of the present disclosure. Thus, those skilled in the art will recognize that various configurations embodying the principles of the present disclosure (even if not explicitly described or shown herein) may be devised within the scope of the present disclosure. Furthermore, any examples described herein should be construed as being intended to aid in the understanding of the principles of the present disclosure, and not as being limited to the specifically enumerated examples and conditions. Consequently, the present disclosure is not limited to the specific embodiments or examples described below, but is limited by the scope of the claims.

[0013] Composite parts can be implemented as airframes. Composite parts (such as carbon fiber reinforced polymer (CFRP) parts) are first laid up in multiple layers collectively referred to as preforms. While individual fibers within each layer of the preform are aligned parallel to one another, different layers can exhibit different fiber orientations to improve strength along various dimensions of the resulting composite part. Alternatively, preforms can include braided fiber fabrics or materials with random or discontinuous fibers. Preforms can contain a viscous resin that solidifies to solidify the preform into a composite part. Carbon fiber impregnated with an uncured thermosetting or thermoplastic resin is referred to as a "prepreg." Other types of carbon fiber include "dry fiber," which is not impregnated with a thermosetting resin but may contain a tackifier or binder. Dry fiber can be infused with resin before curing. For thermosetting resins, solidification is a unidirectional process called curing, while for thermoplastic resins, the resin can reach a viscous form when reheated.

[0014] 1 is a block diagram of a line assembly system 100 that includes an autoclave 180 for solidifying preforms (i.e., curing and reheating thermoset preforms and hardening thermoplastic preforms) into composite parts, in one embodiment. The line assembly system 100 includes any system, device, or component operable to repeatedly pulse a preform 170 in a process direction 179 to form a fuselage half-barrel section (or other arcuate section of a fuselage with skin and stringers). In this embodiment, the line assembly system 100 includes an autoclave 180 that solidifies the preform 170 by applying heat and pressure.

[0015] A preform 170 is laid up on a layup mandrel 120, which moves in a process direction 179 along the factory floor 110 and is driven by an automated guided vehicle (AGV) 130 or along a track 132 to an autoclave 180. The layup mandrel 120 includes a periphery 121. A caul plate 160 (or vacuum bag) is placed over the preform 170 and conforms to an outer shape 162 of the preform 170. A layup surface 123 (see FIG. 5A ) of the layup mandrel 120 defines the outer shape 162 of the preform 170. The caul plate 160 seals the preform 170 to the layup mandrel 120 before sealing the layup mandrel 120 to an inner surface 186 of the autoclave 180. In this embodiment, the caul plate 160 is sealed to the layup mandrel 120 by a vacuum (e.g., by a vacuum system internal to the layup mandrel 120), which applies a consolidation force to the preform 170. In a further embodiment, a vacuum bag (e.g., vacuum bag 714) is utilized to perform this task.

[0016] During operation, the layup mandrel 120 is driven into a hollow portion (e.g., passageway 189) of the autoclave 180 via an inlet 722. While the layup mandrel 120 is inserted into the autoclave 180, the layup mandrel 120 and the autoclave 180, along with the peripheral seal 150 and the backing plate 160, define a pressure chamber 187 (referred to herein as a vacuum chamber, pressure chamber, pressurized chamber, or sealed chamber) for the preform 170. The peripheral seal 150 of the layup 120 abuts and seals against an inner surface 186 of the autoclave 180, such that the autoclave 180 and the layup mandrel 120 together form the pressure chamber 187 in which the preform 170 is heated. That is, the peripheral seal 150 seals the periphery 121 of the layup mandrel 120 to the inner surface 186 of the autoclave 180. In this embodiment, the layup mandrel 120 also includes a gap seal 124, which may include a rigid or other thermal barrier for sealing the gap 310 (e.g., an arc-shaped gap) by clamping the autoclave 180 to form a pressure chamber 187 (i.e., any sealed / sealable chamber capable of supporting a pressure amount different from atmospheric pressure). The gap seal 124 is attached to the layup mandrel 120 by a hinge 125. The gap seal 124 may form an arc shape and may include a rigid segment of material. While a hinge-attached gap seal 124 is described, this is one embodiment of a seal in the autoclave 180; other types of seals may be used to form the pressure chamber 187 by engaging the layup mandrel 120, the caul plate 160, and the autoclave 180.

[0017] The interior surface 186 of the autoclave 180 conforms to and complements the contour 162 of the preform 170, and is only a short distance (e.g., gap 310) from the contour 162 (e.g., less than 10 inches, less than 2 inches, etc.). This means that the heat and pressure applied to the pressure chamber 187 are applied to a smaller volume than in conventional autoclaves, thereby improving heating efficiency and solidification speed. This also means that the autoclave 180 has a smaller thermal mass and that smaller equipment can be used to pressurize the autoclave 180 (e.g., with nitrogen gas or other inert fluid).

[0018] A heater 182 is positioned within the autoclave 180 beneath an insulating shroud 188. In this embodiment, the insulating shroud 188 includes vanes 184, which provide structural reinforcement to the autoclave 180 and facilitate heat dissipation after the autoclave 180 completes a heating cycle. The heater 182 of the autoclave 180 and the heater 122 of the lay-up mandrel 120 may include radiant heaters that increase the temperature of the chamber. In one embodiment, the heaters 122 / 182 are controlled by zone to allow the temperature to remain uniform within a predictable range across the surface of the preform 170. By continuously monitoring and adjusting the amount of heat applied by the heaters 122 / 182 by zone, the temperature of the preform 170 is precisely controlled throughout the preform 170.

[0019] Heaters 122 / 182 are insulated from the exterior of autoclave 180 and the interior of layup mandrel 120 by insulating shroud 188 and insulating shroud 128, respectively. Insulating shroud 128 / 188 may include vacuum-sealed or otherwise insulated areas. A pressure system 190 controls the pressure in pressure chamber 187 during solidification / processing, for example, by drawing a vacuum on pressure chamber 187 or by increasing the pressure in pressure chamber 187. In this embodiment, a vent 183 is also provided for admitting heated gas into vacuum chamber 187, and is formed between layup mandrel 120, autoclave 180, peripheral seal 150, and caul plate 160. The inclusion of the heaters 122 / 182 in the lay-up mandrel 120 and autoclave 180 reduces the distance between the heaters 122 / 182 and the preform 170, thereby improving heat transfer efficiency. The use of a "right sized" pressure chamber 187 with little excess volume ensures that less gas (e.g., nitrogen gas or other inert fluid) is used by the line assembly system 100, thereby reducing material costs as well as thermal cycle times. The pressure chamber 187 described herein therefore reduces the thermal mass and complexity of the autoclave structure, thereby reducing the amount of pressurized gas that needs to be stored.

[0020] In some embodiments, a bladder 199 is disposed in the preform 170 to provide structural support to any suitable hollow interior 170-1 of the preform 170 (e.g., the hollow interior 170-1 of a hat-shaped stringer disposed in the preform 170) to prevent the hollow interior 170-1 from collapsing during processing. Thus, the bladder 199 is disposed beneath the caul plate 160 or vacuum bag used to consolidate the preform 170. In this manner, the bladder 199 supports the hollow interior 170-1 of the preform 170 against compression caused by the pressure applied by the autoclave 180.

[0021] Bladder 199 is in communication with pressure chamber 187 formed by autoclave 180. This means that when pressure chamber 187 is pressurized, bladder 199 is also pressurized and therefore expands. In this manner, bladder 199 is inflated by the pressure from pressure chamber 187.

[0022] After heating, vanes 184 of autoclave 180 facilitate cooling of autoclave 180 to a handling temperature. At this handling temperature, layup mandrel 120 and composite part 714 are removed in process direction 179, and the next layup mandrel 120 can be inserted from upstream. In a further embodiment, two layup mandrels 120 are placed simultaneously in autoclave 180, either in a line or in a parallel configuration. In such an embodiment, each of the layup mandrels 120 can be sealed to autoclave 180 to close a different door / entrance (e.g., entrance 722 or exit 724) of autoclave 180. The next layup mandrel 120 is then inserted into autoclave 180, and the process is repeated. This unique technological configuration, which allows the layup mandrel 120 to partially define the boundary of chamber 187 of autoclave 180, saves both energy and time. Additionally, because autoclave 180 has a smaller thermal mass than conventional autoclaves, autoclave 180 can be heated and cooled quickly, thereby reducing cycle times and increasing throughput.

[0023] In this embodiment, the autoclave 180 itself forms part of the boundary or blocks the passageway 189 between the cleanroom environment 177 and the assembly area / environment (when not operating as a cleanroom environment) 178. For example, the autoclave 180 may be positioned to pass through boundary 192 (e.g., a shroud or wall that prevents dust from entering the cleanroom environment 177, having an entrance 722 to the cleanroom environment 177). Thus, the autoclave 180 forms part of the boundary of the cleanroom environment 177. Once processing of the preform 170 into the composite part 714 is complete, the composite part exits the autoclave 180 via an exit 724 and enters the assembly area 178.

[0024] Stated differently, autoclave 180 includes an inner surface 186 configured to slidingly receive layup mandrel 120 and to mate with layup mandrel 120 to form pressure chamber 187 after layup mandrel 120 is slidingly received therein. Autoclave 180 further defines an arcuate or curved gap 310 defined by inner surface 186 that is configured to receive seal 124 that seals layup mandrel 120 to inner surface 186. The layup mandrel 120 defines a contour suitable for the preform 170 and includes a peripheral seal 150 that seals the layup mandrel 120 to the autoclave 180 as the layup mandrel 120 slides into the autoclave 180, and a gap seal 124 that seals a gap 310 (e.g., an arcuate gap) between the layup mandrel 120 and the autoclave 180 after the layup mandrel 120 slides into the autoclave 180. In this manner, the arcuate layup mandrel 120 and the arcuate autoclave 180 form complementary arcs.

[0025] In one embodiment, the preform 170 is heated in an autoclave 180. The autoclave 180 is operated as a dedicated station, with a full-length pulse motion corresponding to the length of a fuselage half-barrel section. Thus, there may be an assembly line for layup before the autoclave 180 and another assembly line after the autoclave 180, with the upper and lower half-barrel sections being placed in-line on such line. If the lower half-barrel section is downstream of the upper half-barrel section, the lower half-barrel section may undergo various operations before its corresponding upper half-barrel section. For example, the lower half-barrel section may be solidified before the upper half-barrel section, receive a frame before the upper half-barrel section, and so on. In one embodiment, the upper and lower half-barrel sections are co-cured in a tandem autoclave, with the lower half-barrel section exiting the autoclave first and entering the assembly line. In one embodiment, the two half-barrel sections are processed simultaneously by the same autoclave 180. Multiple layup mandrels 120 for half barrel sections are arranged side-by-side and sealed together or individually to the autoclave 180 and processed simultaneously.

[0026] Controller 197 includes processor 197-1 and memory 197-2 and manages the various components described herein (including, for example, heaters 122 / 182, pressure system 190, autoclave 180, etc.) to perform the methods described herein. In one embodiment, controller 197 is implemented as custom circuitry, as a hardware processor executing programmed instructions stored in memory, or some combination thereof.

[0027] Further details of the operation of the line assembly system 100 are described in relation to Figure 2. This embodiment assumes that the layup mandrel 120 has already received the preform 170, which has been sealed onto the layup mandrel 120 by the addition of the caul plate 160. The preform 170 is then ready to be consolidated into a composite part 714.

[0028] FIG. 2 is a flow diagram illustrating a method for operating a line assembly system to solidify preforms in an autoclave, according to an exemplary embodiment. The steps of method 200 are described with reference to line assembly system portion 100 of FIG. 1 , although one skilled in the art will recognize that method 200 may be implemented in other systems. The steps described herein in the flow diagrams are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order. Furthermore, although the steps described herein are for a half-barrel section, they may be applied to any suitable arcuate section of a fuselage (e.g., a full-barrel section, a quarter-barrel section, or other segment sizes). In a further embodiment, the autoclave is sized to solidify any suitable structure (e.g., a wing panel, a spar, a frame, a floor beam, a stabilizer, a door, etc.). In such cases, the autoclave's insulating shroud 188 is sized and shaped to complement the contours of the layup mandrel 120 for such components, and a peripheral seal 150 is used to seal the layup mandrel 120 to the autoclave 180. In one embodiment, prior to sealing, a bladder 199 is placed on the preform 170 (optional step 200-1). Such a bladder 199 provides structural support to one or more hollow interiors 170-1 of the preform 170.

[0029] Step 201 involves sealing the caul plate 160 to the layup mandrel 120 over the preform 170. This may involve tape sealing, suction bonding, vacuum sealing, or otherwise securing the caul plate 160 against the preform 170 while preventing airflow from reaching the preform 170 beyond the caul plate 160. Step 202 involves advancing the layup mandrel 120 holding the preform 170 in a process direction 179. This may involve driving the layup mandrel 120 by an AGV 130 or advancing the layup mandrel 120 by a track 132 coupled to an autoclave 180. In one embodiment, the layup mandrel 120 has already been advanced in the process direction 179 through multiple layup stations and one preparation station (where the preform 170 is sealed to the layup mandrel 120). This involves sealing the caul plate 160 to the layup mandrel 120 before driving the layup mandrel 120 into the autoclave 180. In such an embodiment, the caul plate 160 itself acts as a vacuum bag for the preform 170.

[0030] Step 204 includes aligning the layup mandrel 120 for insertion into the autoclave 180, which has an inner surface 186 that conforms to / complements the outer shape 162 of the preform 170. This may include positioning the layup mandrel 120 so that it is inserted into the autoclave 180 through the inlet 722 by being driven in the process direction 179. Thus, unlike autoclaves in which the autoclave itself defines all of the walls / boundaries of the pressure chamber, the autoclave 180 of method 200, together with the layup mandrel 120 and, if present, the peripheral seal 150, the gap seal 124, and / or the shroud 128, form the pressure chamber 187. These seals and / or the shroud engage the autoclave shroud 188, which may be open longitudinally on the factory floor.

[0031] In step 206, the AGV 130 (or tug or manual cart) drives the lay-up mandrel 120 in the process direction 179 into the autoclave 180 via the entrance 722. This causes the preform 170 to nest with the inner surface 186 of the autoclave 180. This may include aligning the peripheral seal 150 with complementary features 185 (e.g., grooves or protrusions) on the inner surface 186 and mating the peripheral seal 150 with the complementary features 185 on the inner surface 186 to form an airtight boundary. In further embodiments, the airtight seal is formed without the need for complementary features 185 by carefully sizing the peripheral seal 150. Because the inner surface 186 conforms to the outer contour 162, driving the layup mandrel 120 into the autoclave 180 creates a gap 310 of less than 10 inches (e.g., less than 2 inches) between the inner surface 186 of the autoclave 180 and the outer contour 162 of the preform 170. An airtight seal may also be achieved by compressing a flexible coating or liner of the peripheral seal 150 as it is driven into the complementary feature 185 of the autoclave 180. In a further embodiment, a pair of layup mandrels 120 are positioned in line within the autoclave 180. For example, both pairs of layup mandrels 120 holding separate half barrel sections (which will later be joined to form a full barrel section after the half barrel sections have solidified and been demolded) may be placed in line within the autoclave 180, with one layup mandrel 120 downstream from the other layup mandrel 120 within the autoclave 180. Sealing a vacuum bag 717 to the layup mandrels 120 (optional step 207) may be performed prior to sealing the layup mandrels 120 within the autoclave 180.

[0032] In step 208, the layup mandrel 120 is sealed within the autoclave 180. This may include sealing the gap 310 between the layup mandrel 120 and the autoclave 180 at one or both ends of the autoclave 180 along the process direction 179 (e.g., the inlet 722 and the outlet 724). Sealing may include taping the gap closed or closing the gap with a solid clamp plate (not shown) that acts as an intermediate between the inner surface 186 and the layup mandrel 120. In some embodiments, sealing may include sealing a gap seal 124 that seals the gap 310 between the layup mandrel 120 and the autoclave 180 after the layup mandrel 120 slides into the autoclave 180. In one embodiment, the periphery 121 of the layup mandrel 120 is sealed against the inner surface 186 of the autoclave 180 (optional step 209). In embodiments in which multiple layup mandrels 120 are arranged within the autoclave (e.g., in a row), each layup mandrel 120 may seal a separate inlet (e.g., inlet 722 or outlet 724) (or a portion thereof) of the autoclave 180. When the layup mandrels 120 are arranged in a row, each may be sealed separately, or the layup mandrels 120 may utilize a tandem sealing / bonding technique (one layup mandrel 120 forms an upstream seal with the autoclave 180 and another layup mandrel 120 forms a downstream seal with the autoclave 180). After sealing is complete, the layup mandrels 120 define the lower boundary of the autoclave 180 (i.e., the lower boundary of the pressure chamber 187 in the autoclave 180). In one embodiment, sealing the lay-up mandrel 120 within the autoclave 180 includes sealing the arcuate gap 310 between the preform 170 and the interior surface 186 of the autoclave 180 .

[0033] Step 210 involves solidifying the preform 170 into the composite part 714 by applying heat and pressure within the autoclave 180. In the case of a thermosetting preform, this involves heating the preform 170 to a cure temperature and applying pressure to solidify the preform 170 into the desired shape. In the case of a thermosetting preform, this may involve raising the temperature of the preform 170 to the melting point of the thermoplastic material within the preform 170, solidifying the preform 170 under pressure, and cooling the preform 170 until it solidifies / sets into the composite part 714. Solidifying the preform 170 may include activating a heater 122 within the layup mandrel 120 located below the preform 170 (e.g., below the layup surface 123) and / or activating a heater 182 within the autoclave 180 located outside the interior surface 186. Heaters 182 and / or 122 may include resistive heaters 126, susceptors 127 that are responsive to electromagnetic fields, etc. During solidification, one or more bladders 199 may support one or more hollow interiors 170-1 of preform 170 against compressive forces caused by pressure applied by autoclave 180 (optional step 211).

[0034] After the composite part 714 is solidified, the autoclave 180 is unsealed and the layup mandrel 120 may exit the autoclave 180 via an exit 724 and move in a process direction 179 for further operations to be performed. Step 212 includes removing the caul plate 160, performing any desired post-solidification trimming or processing, and demolding the composite part 714. Additional operations are then performed on the composite part 714 (e.g., installing a frame in the composite part or installing a window in the composite part), and the layup mandrel 120 is cleaned.

[0035] 3 is a perspective view of a preform 170 being inserted into an autoclave 180 (e.g., beneath an insulating shroud 188 of the autoclave 180) in one exemplary embodiment. FIG. 3 illustrates how the layup mandrel 120 defines the boundary of the autoclave 180 in the process direction 179 and further illustrates the peripheral seals 150 interlocking with the autoclave 180. The gap seals 124 engage the shroud 188 of the autoclave 180 to seal both ends of the layup mandrel 120 in place. That is, the gap seals 124 close the pressure chamber 187 by bridging the gap between the layup mandrel 120 and the autoclave 180 (e.g., at the inlet 722 and outlet 724 (not shown in FIG. 3 )).

[0036] 3 further illustrates that a narrow (i.e., less than 10 inches) arcuate gap 310 remains between the lay-up mandrel 120 and the interior surface 186 of the autoclave 180 along the entire contour 162 of the preform 170. That is, the space between the lay-up mandrel 120 and the autoclave 180 is designed to be kept to a minimum to eliminate wasted void space that must be heated and / or pressurized during operation. This reduction in stored energy dramatically reduces safety efforts and system complexity compared to conventional autoclaves. This space reduction allows for zoned or localized control of heating and pressure, if desired.

[0037] 4 is a perspective view of an autoclave 180 with a layup mandrel 120 inserted in one exemplary embodiment. In this embodiment, a single layup mandrel 120 is placed in the autoclave 180. However, in further embodiments, multiple layup mandrels 120 may be placed in the autoclave 180 at one time for curing.

[0038] Figure 5A, which corresponds to the perspective of arrow 5A in Figure 4, shows layup mandrel 120 before layup, awaiting entry into autoclave 180. Layup surface 123 of layup mandrel 120 defines contour 162, and layup mandrel 120 includes heater 122 below layup surface 123. In Figure 5B, the layup is complete, with layup mandrel 120 covered by preform 170 and caul plate 160.

[0039] 5C is an end view of the autoclave 180 of FIG. 4 in an exemplary embodiment, corresponding to the perspective of arrow 5C in FIG. 4. FIG. 5C reveals that the gap 310 between the heaters 122 and 182 is sealed by a cover 500 disposed between the layup mandrel 120 and the autoclave 180. The cover 500 is annular in shape and may comprise a rigid tool or a flexible component that insulates and is sealed to the autoclave 180. In this embodiment, the autoclave 180 forms the upper boundary 512 of the pressure chamber 510, while the layup mandrel 120 (or a caul plate or preform molded thereby) may have a seal applied to region 5E to form the pressure chamber 187 that forms the lower boundary 514 of the pressure chamber 510.

[0040] 5D is a diagram of an additional layup mandrel 560 and autoclave 550 for a wing panel, in one exemplary embodiment. In this embodiment, layup mandrel 560 is inserted into autoclave 550, which includes support 552, lower wall 554, and upper wall 556. Preform 580 is laid up on contour 562 of layup mandrel 560, and backing plate 570 covers preform 580. Upper wall 556, support 552, and backing plate 570 together form a pressure chamber 590 for solidifying preform 580. Peripheral seals 592 define the boundaries of pressure chamber 590 on the near and far sides of the page. Peripheral seals 592 accommodate the various dimensions of layup mandrels for different component sizes.

[0041] Figure 5E illustrates various sealing arrangements for the autoclave 180 in one exemplary embodiment, corresponding to region 5E of Figure 5C. In a first configuration 500-10, shown on the left, the sealing portion 500-40 is in direct contact with the autoclave wall 500-30 and also with the backing plate 500-50, which is in direct contact with the layup mandrel surface 500-20. In a second configuration 500-12, the sealing portion 500-40 is in direct contact with the backing plate 500-50, which is itself in direct contact with the autoclave wall 500-30. The sealing portion 500-40 is also in direct contact with the layup mandrel surface 500-20. In the third configuration 500-14, the sealing portions 500-40 individually bridge between the autoclave wall 500-30 and the lay-up mandrel face 500-20, with the caul plate 500-50 terminating before reaching the sealing portions 500-40.

[0042] FIG. 6 is a side view of a layup mandrel 610 including an extension region for sealing against an autoclave, according to one exemplary embodiment. The layup mandrel 610 can be used to facilitate the production of a section of a fuselage that has a smaller cross-section or length than other sections of the fuselage to be produced by the autoclave. The layup mandrel 610 itself has a length L corresponding to the length of the autoclave and includes extension regions 620 and 630 having heights H (and / or cross-sectional arcs) corresponding to the inlet / outlet of the autoclave. Therefore, extension regions 620 and 630 can be sealed against the autoclave because the layup mandrel 610 is sized to fit the autoclave, regardless of the size of the preform to be solidified. At the same time, the layup region 640 is sized to provide an appropriate profile for a preform that is smaller than the other preforms used in the autoclave. Thus, the layup area 640 may exhibit a smaller diameter, height, or length than the autoclave, but this is compensated for by the dimensions of the layup mandrel 610 .

[0043] FIG. 7 is a top view of an autoclave and preparation station in one exemplary embodiment. FIG. 7 shows layup mandrels 710 receiving preforms 170 and receiving caul plates 716 and / or vacuum bags 717 at a preparation station 718. The layup mandrels 710 are aligned for insertion into an autoclave 720. The autoclave 720 has an inlet 722 at a first location and an outlet 724 at a second location a distance away in a process direction 779. In one embodiment, the autoclave 720, inlet 722, and outlet 724 are all arc-shaped. The above process, with geometric modifications as needed, can be utilized to facilitate the production of wing panels, spars, ribs, or frames. The autoclave 720 forms a portion of an arc-shaped pressure chamber, which is completed by inserting the layup mandrels 710 into the autoclave 720 and sealing the layup mandrels 710 in place.

[0044] After exiting the autoclave 720, the layup mandrel 710 moves to a debag station 730 where removal of the caul plate 716 and / or vacuum de-bagging occurs, where the composite part 714 is stripped from the layup mandrel 710. The layup mandrel 710 and caul plate 716 are then cleaned and returned to the start of the manufacturing line to receive a new preform 170 for the composite part 714. The composite part 714 continues in a process direction 779 for post-cure processing (e.g., receiving fasteners, installing windows, etc.) to become an aircraft. This process ensures that the layup mandrel 710 and caul plate 716 can be quickly and efficiently reused without creating waste product and without requiring costly amounts of space on the factory floor.

[0045] 8-11 are flow diagrams illustrating additional techniques for operating a layup mandrel and a complementary autoclave in exemplary embodiments. These methods will now be described in the context of the autoclave 180 of FIG. 1. FIG. 8 illustrates a method 800 for sealing the autoclave 180. The method includes, in step 802, driving or inserting the layup mandrel 120 in the process direction 179 into the autoclave 180, and, in step 804, sealing the inlet 722 (and optionally the outlet 724) of the autoclave 180 with a seal 124 attached to the layup mandrel 120. Sealing the inlet 722 may include clamping the seal 124 to the autoclave 180 (optional step 806). Thus, according to the process described above, the layup mandrel 120 is positioned within a desired distance (e.g., gap 310) from the autoclave 180 (e.g., shroud 188 of the autoclave 180). A bladder 199 in the layup mandrel 120 allows it to receive pressure from the autoclave 180. The periphery 121 of the layup mandrel 120 is sealed against the autoclave 180 to form a pressure chamber 187, which is then pressurized.

[0046] In another embodiment, the method further includes heating the preform 170 on the layup mandrel 120 with a heater 182 of the autoclave 180 and / or heating the preform 170 on the layup mandrel 120 with a heater 122 of the layup mandrel 120. In a further embodiment, the method further includes securing the preform 170 to the layup mandrel 120 by sealing an edge of the caul plate 160 to the layup mandrel 120. In yet another embodiment, driving the layup mandrel 120 into the autoclave 180 creates a pressure chamber 187 between the layup mandrel 120 and the autoclave 180. This involves bringing three separate elements (perimeter seal 150, caul plate 160, and autoclave 180) together to form the pressure chamber 187, and then removing some of the components when solidification is complete. In yet a further embodiment, the method also includes driving the layup mandrel 120 in the process direction 179 to exit the autoclave 180 via the outlet 724. In yet another embodiment, sealing the inlet 722 includes forming an insulating barrier by sealing the arcuate gap 310 between the layup mandrel 120 and the autoclave 180 (optional step 808). The concepts described herein may be utilized for any suitable composite part (e.g., wing panels, ribs, spars, and / or frames for an aircraft fuselage). In such an embodiment, the shroud 188 of the autoclave 180 is dimensioned (i.e., sized and shaped) to compensate for the contour (e.g., contour 562 of FIG. 5D ) of the layup mandrel 120 on which the preform 170 is placed. This compensatory aspect allows the layup mandrel 120 itself to form the boundary of the autoclave 180, and allows the peripheral seal 150 to be used to seal the autoclave 180 and the layup mandrel 120 together.

[0047] 9 illustrates a method 900 for forming a pressure chamber 187 in an autoclave 180. The method includes, in step 902, driving a layup mandrel 120 in a process direction 179 into the autoclave 180, in step 904, forming a pressure chamber 187 having a boundary defined by the layup mandrel 120 and the autoclave 180, and, in step 905, inflating one or more bladders 199 in a preform 170 laid up on the layup mandrel 120 with pressure from the pressure chamber 187, the bladders 199 supporting the hollow interior 170-1 of the preform 170 against compression. The method 900 further includes, in step 906, solidifying the preform 170 in the layup mandrel 120 into a composite part 714. Consolidating the preform 170 includes heating the preform 170 using the heater 122 of the layup mandrel 120 and / or the heater 182 of the autoclave 180 (optional step 912). In further embodiments, consolidating the preform 170 may include pressurizing the pressure chamber 187 using heated gas from the pressure system 190 of the autoclave 180 (optional step 914). The method 900 further includes removing the layup mandrel 120 in step 908.

[0048] In a further embodiment, driving the layup mandrel 120 is performed by an autonomous guided vehicle (AGV) 130, a cart, wheels, etc. In a further embodiment, the method 900 also includes demolding the composite part 714 from the layup mandrel 120 (optional step 910).

[0049] In a further embodiment, the autoclave 180 forms a first boundary of the pressure chamber 187, the layup mandrel 120 forms a second boundary of the pressure chamber 187, and the peripheral seal 150 forms a third boundary. In a further embodiment, the pressure chamber 187 is arc-shaped, and forming the pressure chamber 187 includes sealing a gap 310 (and the longitudinal edges) between the layup mandrel 120 and the autoclave 180 (see step 804 of FIG. 8). In yet another embodiment, sealing the arc-shaped gap 310 includes forming an insulating (and pressure-retaining) barrier (see step 808 of FIG. 8).

[0050] 10 shows a method 1000 of sealing an autoclave 180. The method includes, in step 1002, driving a layup mandrel 120 in a process direction 179 (e.g., by AGV, on rails, manually, etc.) into the autoclave 180, and, in step 1004, heating a preform 170 on the layup mandrel 120 by a heater 122 disposed in the layup mandrel 120 and by a heater 182 disposed in the autoclave 180. Heating the preform 170 may include passing an electric current through a resistance heater 126 in the layup mandrel 120 and the autoclave 180 (optional step 1006) or applying an electromagnetic field to a susceptor 127 in the layup mandrel 120 and the autoclave 180 (optional step 1008). In yet a further embodiment, preform 170 is heated by pressurized heated gas pumped into pressure chamber 187 of autoclave 180. In yet a further embodiment, heating preform 170 includes raising the temperature of preform 170 to a cure temperature of the thermosetting resin in preform 170 (optional step 1010), or heating preform 170 includes raising the temperature of preform 170 to a melting temperature of the thermoplastic resin in preform 170 (optional step 1012), after which preform 170 is cooled below the melting temperature.

[0051] In a further embodiment, the method 1000 further includes securing the preform 170 to the layup mandrel 120 by sealing an edge of the caul plate 160 to the layup mandrel 120. The method 1000 may further include driving the layup mandrel 120 in a process direction 179 out of the autoclave 180 after the preform 170 has solidified. Furthermore, the method 1000 may include sealing the gap 310 between the layup mandrel 120 and the autoclave 180 with an insulating barrier (e.g., a seal) prior to heating. The layup mandrel 120 is sized to exit the autoclave 180 by moving in the same process direction 179 as the layup mandrel 120 was inserted into the autoclave 180. Furthermore, the layup mandrel 120 forms a lower boundary of the chamber 187 of the autoclave 180 while inserted into the autoclave 180.

[0052] 11 illustrates a method 1100 of sealing an autoclave 180 in one exemplary embodiment. The method 1100 includes, in step 1102, driving a layup mandrel 120 in a process direction 179 (e.g., by an AGV 130, rail, manual cart, etc.) into the autoclave 180 and, in step 1104, sealing the layup mandrel 120 to the autoclave 180 with seals 124 / 150 to form a pressure chamber 187 bounded by the layup mandrel 120 and the autoclave 180. The method 1100 further includes, in step 1106, solidifying a preform 170 in the layup mandrel 120 into a composite part 714 and, in step 1108, driving the layup mandrel 120 in the process direction 179 out of the autoclave 180. Autoclave 180 acts as a portal between the pre-cure / cleanroom environment 177 and the post-cure environment (eg, assembly area 178).

[0053] In a further embodiment, driving the layup mandrel 120 is performed by an autonomous guided vehicle (AGV) 130. The method 1100 may further include demolding the composite part 714 from the layup mandrel 120 (optional step 1110). In one embodiment, solidifying the preform 170 includes heating the preform 170 using a heater 122 of the layup mandrel 120 and / or a heater 182 of the autoclave 180 (see step 912 of FIG. 9 ). In one embodiment, driving the layup mandrel 120 into the autoclave 180 (i.e., after the peripheral seal 150 and / or other seals are in place) forms a pressure chamber 187 between the layup mandrel 120 and the autoclave 180. In a further embodiment, the layup mandrel 120 is moved out of the clean room environment 177 by driving the layup mandrel 120 in the process direction 179 out of the autoclave 180. That is, the layup mandrel 120 remains in the clean room environment 177 during layup and preparation, and then is moved into the autoclave 180, which forms the boundary between the clean room environment 177 and a non-clean room environment (e.g., assembly area 178). After solidification is complete, the layup mandrel 120 proceeds out of the autoclave 180 and into the non-clean room environment, where demolding and trimming occur. The layup mandrel 120 is then cleaned and returned to the clean room environment 177 to receive a preform 170 for another composite part 714.

[0054] In one embodiment, sealing the layup mandrel 120 to the autoclave 180 includes sealing the arc gap 310 between the layup man 120 and the autoclave 180 (see step 804 of FIG. 8). Sealing the arc gap 310 may include forming an insulating barrier between the autoclave 180 and the layup mandrel 120 (see step 808 of FIG. 8).

[0055] 12 illustrates a method 1200 of sealing an autoclave 180 in one exemplary embodiment. The method 1200 includes, in step 1202, removing the preforms 170 on the layup mandrel 120 from the clean room 177 and aligning them with the autoclave 180. In one embodiment, a caul plate 160 is placed over the preforms 170 and fits over the layup mandrel 120. Step 1204 includes sealing the layup mandrel 120 to the autoclave 180. In one embodiment, this results in a pressure chamber 187 between the caul plate 160 and the autoclave 180. The pressure chamber 187 is bounded on one side of the caul plate 160 and on the other side by the autoclave 180. Step 1204 further includes, in step 1206, solidifying the preform 170 into a composite part 714 in an autoclave 180, and, in step 1208, removing the layup mandrel 120 from the autoclave 180. As the layup mandrel 120 exits the autoclave 180, it completely leaves the clean room environment 177 and enters the assembly environment 178, where demolding and trimming of the resulting composite part 714 is performed.

[0056] 13 illustrates a method 1300 for moving a preform 170 out of a clean room 177 in one example embodiment. The method includes, in step 1302, moving the preform 170 on the layup mandrel 120 from the clean room 177 and aligning it with an autoclave 180, and, in step 1304, sealing the layup mandrel 120 to the autoclave 180 using a peripheral seal 150. Sealing the layup mandrel 120 to the autoclave 180 creates a pressure chamber 187 around the preform 170. The method 1300 further includes, in step 1306, processing the preform 170 in the autoclave 180. Processing the preform 170 may include curing the preform 170 (optional step 1310), pressurizing the pressure chamber 187 formed by the layup mandrel 120 and the autoclave 180 (optional step 1312), or other processing actions. The method 1300 further includes, in step 1308, removing the layup mandrel 120 from the autoclave 180 and placing it in a non-clean room (e.g., assembly area 178).

[0057] In the following examples, further processes, systems, and methods are described in terms of an autoclave in a continuous line assembly environment.

[0058] Referring more particularly to the drawings, embodiments of the present disclosure may be described in terms of aircraft manufacturing and service in a method 1400 as shown in Figure 14 and in terms of an aircraft 1402 as shown in Figure 15. During pre-production, the method 1400 may include specification and design 1404 of the aircraft 1402 and material procurement 1406. During production, component and subassembly manufacturing 1408 and system integration 1410 of the aircraft 1402 occurs. The aircraft 1402 may then undergo certification and delivery 1412 and be placed into service 1414. While in customer operation, the aircraft 1402 is scheduled for periodic maintenance and service 1416, which may include modification, reconfiguration, refurbishment, etc. Apparatus and methods embodied herein may be used during one or more of any suitable stages of manufacturing and maintenance described in method 1400 (e.g., specification and design 1404, materials procurement 1406, component and subassembly manufacturing 1408, system integration 1410, certification and delivery 1412, operation 1414, maintenance and service 1416) and / or any suitable component of aircraft 1402 (e.g., airframe 1418, systems 1420, interior 1422, propulsion system 1424, electrical system 1426, hydraulic system 1428, environmental system 1430).

[0059] Each of the processes of method 1400 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). As used herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military organization, a service organization, etc.

[0060] 15 , an aircraft 1402 produced by method 1400 may include an airframe 1418 having a number of systems 1420 and an interior 1422. Examples of systems 1420 include one or more of a propulsion system 1424, an electrical system 1426, a hydraulic system 1428, and an environmental system 1430. Any number of other systems may also be included. While an aerospace example is shown, the principles of the present disclosure may be applied to other industries, such as the automotive industry.

[0061] As mentioned above, apparatus and methods embodied herein may be used in any one or more stages of manufacturing and maintenance described in method 1400. For example, components or subassemblies corresponding to component and subassembly manufacturing 1408 may be fabricated or manufactured in a manner similar to components or subassemblies manufactured during the service life of aircraft 1402. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized in subassembly manufacturing 1408 and system integration 1410, for example, by significantly reducing the assembly or cost of aircraft 1402. Similarly, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the service life of aircraft 1402 (for example, but not limited to, in maintenance and service 1416). For example, the techniques and systems described herein may be used in material procurement 1406, component and subassembly manufacturing 1408, system integration 1410, operation 1414, and / or maintenance and service 1416, and / or may be used in airframe 1418 and / or interior 1422. These techniques and systems may also be utilized in systems 1420, including, for example, propulsion system 1424, electrical system 1426, hydraulic system 1428, and / or environmental system 1430.

[0062] In one embodiment, a part comprises a portion of the airframe 1418 and is manufactured in component and subassembly manufacturing 1408. The part may then be incorporated into the aircraft in system integration 1410 and subsequently utilized in service 1414 until wear renders it unusable. The part may then be discarded and replaced with a newly manufactured part in maintenance and service 1416. Inventive components and methods may be utilized throughout component and subassembly manufacturing 1408 to manufacture the new part.

[0063] Any of the various control elements (e.g., electrical components or electronic components) shown in the figures or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors,” “controllers,” or some similar terminology. When provided by a processor, functionality may be provided by a single dedicated processor, by a single shared processor, or by multiple individual processors, some of which may be shared. Furthermore, explicit use of the terms “processor” or “controller” should not be construed as referring solely to hardware capable of executing software, but may implicitly include, without limitation, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random-access memory (RAM), non-volatile storage, logic, or any other physical hardware component or module.

[0064] Also, a control element may be implemented as instructions executable by a processor or computer to perform the function of the element. Some examples of instructions are software, program code, and firmware. When executed by a processor, the instructions are operable to instruct the processor to perform the function of the element. The instructions may be stored in a storage device readable by the processor. Some examples of storage devices are digital or solid-state memory, magnetic storage media (such as magnetic disks and magnetic tapes), hard drives, or optically readable digital data storage media.

[0065] The following sections describe illustrative, non-exclusive examples that provide background technology that is helpful in understanding the present invention.

[0066] According to one aspect of the present disclosure, a method (200) for consolidating a preform (170) into a composite part (714) is disclosed, the method comprising: Aligning (204) a layup mandrel (120) holding a preform (170) for insertion into an autoclave (180), the autoclave (180) having an inner surface (186) complementary to the outer shape (162) of the preform (170); and sealing (208) the lay-up mandrel (120) in the autoclave (180).

[0067] Optionally, the method The method further includes driving (206) the lay-up mandrel (120) in a process direction (179) into the autoclave (180) to nest the preform (170) with the interior surface (186) of the autoclave (180).

[0068] Optionally, the lay-up mandrel (120) is driven (206) into the autoclave (180) to create a gap (310) of less than 25.4 centimeters (10 inches) between the inner surface (186) of the autoclave (180) and the outer shape (162) of the preform (170).

[0069] Optionally, the method The method further includes applying heat in the autoclave to consolidate (210) the preform (170) into a composite part (714). Optionally, consolidating (210) the preform includes applying heat by a heater (122) positioned below the preform (170) in the lay-up mandrel (120).

[0070] Optionally, solidifying (210) the preform (170) includes applying heat by a heater (182) disposed outside the interior surface (186) within the autoclave (180).

[0071] Optionally, an autoclave (180) forms the boundary (192) between the cleanroom environment (177) and the assembly environment (178).

[0072] Optionally, sealing (201) the caul plate (160) to the lay-up mandrel (120) before sealing the lay-up mandrel in the autoclave (180).

[0073] Optionally, the method The method further includes sealing (207) a vacuum bag (717) to the lay-up mandrel (120) before sealing the lay-up mandrel (120) in the autoclave (180).

[0074] Optionally, sealing (208) the layup mandrel (120) within the autoclave (180) includes sealing an arcuate gap (310) between the preform (170) and the inner surface (186) of the autoclave (180). Optionally, sealing (208) the layup mandrel (120) within the autoclave (180) includes sealing (209) a periphery of the layup mandrel (120) to the inner surface of the autoclave (180).

[0075] Optionally, the lay-up mandrel (120) forms the lower boundary (514) of the chamber of the autoclave (180).

[0076] Optionally, the method The method further includes disposing (200-1) a bladder (199) on the preform (170) that provides structural support to the hollow interior (170-1) of the preform (170).

[0077] Optionally, the method The method further includes supporting (211) the hollow interior (170-1) of the preform (170) against compression caused by pressure applied by the autoclave (180).

[0078] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method (200) in any one of the preceding examples.

[0079] According to one aspect of the present disclosure, a non-transitory computer-readable medium (197-2) embodying programmed instructions, the instructions when executed by a processor (197-1), is operable to perform a method for solidifying a preform (170) into a composite part (714), the method comprising: Aligning a lay-up mandrel (120) holding a preform (170) for insertion into an autoclave (180), the autoclave (180) having an inner surface (186) complementary to the outer shape (162) of the preform; and sealing the lay-up mandrel (120) in an autoclave (180).

[0080] Optionally, the method The method further includes driving the lay-up mandrel (120) in a process direction (179) into the autoclave (180) to nest the preform (170) with an inner surface (186) of the autoclave (180). Optionally, driving the lay-up mandrel (120) into the autoclave (180) creates a gap (310) of less than 10 inches between the inner surface (186) of the autoclave (180) and the outer shape (162) of the preform (170).

[0081] Optionally, the method The method further includes applying heat within the autoclave to consolidate the preform into a composite part. Optionally, consolidating the preform includes applying heat via a heater disposed beneath the preform within the lay-up mandrel. Optionally, consolidating the preform includes applying heat via a heater disposed outside an interior surface of the autoclave.

[0082] Optionally, an autoclave (180) forms the boundary (192) between the cleanroom environment (177) and the assembly environment (178).

[0083] Optionally, the method The method further includes driving the lay-up mandrel (120) in a process direction (179) out of the autoclave (180).

[0084] Optionally, the method The method further includes sealing a caul plate (160) to the layup mandrel (120) before sealing the layup mandrel (120) in the autoclave (180).

[0085] Optionally, the method The method further includes sealing a vacuum bag (717) to the lay-up mandrel (120) before sealing the lay-up mandrel (120) in the autoclave (180).

[0086] Optionally, sealing the lay-up mandrel in the autoclave includes sealing an arcuate gap (310) between the preform and the inner surface of the autoclave and sealing a periphery (121) of the lay-up mandrel to the inner surface of the autoclave.

[0087] Optionally, a lay-up mandrel forms the lower boundary (514) of the chamber (187) of the autoclave.

[0088] Optionally, the method The method further includes disposing a bladder (199) on the preform that provides structural support to the hollow interior (170-1) of the preform.

[0089] Optionally, the method It further includes supporting the hollow interior (170-1) of the preform against compression caused by pressure applied by the autoclave.

[0090] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed that is assembled according to a method defined by instructions stored on a computer-readable medium (197-2) as set forth in any one of the preceding examples.

[0091] According to one aspect of the present disclosure, a system (100) for consolidating a preform (170) into a composite part (714) is disclosed, the system comprising: a layup mandrel (120) having a layup surface (123) defining a contour (162) suitable for a preform (170); an autoclave (180) sized to receive the layup mandrel (120) such that the layup mandrel (120) defines a boundary of a chamber (187) of the autoclave, the autoclave (180) including an inner surface (186) complementary to the outer shape (162) of the layup mandrel (120).

[0092] Optionally, the layup mandrel (120) further comprises a heater (122) disposed below the layup surface (123).

[0093] Optionally, the autoclave (180) further comprises an insulating shroud (188).

[0094] Optionally, the space between the inner surface (186) and the outer surface (162) is less than 10 inches.

[0095] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0096] According to one aspect of the present disclosure, a method (1300) for moving a preform (170) out of a clean room (177) is disclosed, the method comprising: removing (1302) the preform (170) on the lay-up mandrel (120) from the clean room (177); sealing (1304) the lay-up mandrel (120) in an autoclave (180); treating (1306) the preform (170) in an autoclave (180); and removing (1308) the layup mandrel (120) from the autoclave (180), whereby the layup mandrel (120) enters an assembly environment (178) separate from the clean room (177).

[0097] Optionally, moving (1302) the preform (170) on the layup mandrel (120) includes moving the layup mandrel (120) into alignment with the autoclave (180).

[0098] Optionally, sealing (1304) the lay-up mandrel (120) to the autoclave (180) includes sealing the curved gap (310) between the lay-up mandrel (120) and the autoclave (180).

[0099] Optionally, the lay-up mandrel (120) is sealed (1304) in an autoclave (180) to form a pressure chamber (187) in which the preform (170) is solidified.

[0100] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) according to a method (1300) as in any one of the previous examples is disclosed.

[0101] According to one aspect of the present disclosure, an apparatus in the form of an autoclave (180) is disclosed, the apparatus comprising: The inner (186) and a curved gap (310) defined by an inner surface (186) having dimensions corresponding to the dimensions of the lay-up mandrel (120).

[0102] Optionally, the autoclave (180) further comprises a heater (182) for heating the preform (170) disposed on the lay-up mandrel (120).

[0103] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using an apparatus as described in any one of the previous examples is disclosed.

[0104] According to one aspect of the present disclosure, an apparatus in the form of a lay-up mandrel (120) is disclosed, the apparatus comprising: a layup surface (123) defining a contour (162) suitable for the preform (170); a first sealing portion (150) that seals the layup mandrel (120) to the autoclave (180) when the layup mandrel (120) is advanced into the autoclave (180); and a second sealing portion (124) that seals the arcuate gap (310) between the layup mandrel (120) and the autoclave (180) after the layup mandrel (120) is advanced into the autoclave (180).

[0105] Optionally, the layup mandrel (120) further comprises a heater (122) disposed below the layup surface (123) for heating the preform (170) disposed on the layup mandrel (120).

[0106] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using an apparatus as described in any one of the previous examples is disclosed.

[0107] According to one aspect of the present disclosure, a method (900) for forming a pressure chamber (187) in an autoclave is disclosed, the method comprising: driving (902) the lay-up mandrel (120) in a process direction (179) into an autoclave (180); forming (904) a pressure chamber (187) having boundaries defined by the lay-up mandrel (120), the autoclave (180), and the peripheral seal (150); consolidating (906) the preform (170) on the lay-up mandrel (120) into a composite part (714); and removing (908) the lay-up mandrel (120).

[0108] Optionally, driving (902) the lay-up mandrel (120) is performed by an autonomous guided vehicle (AGV) (130).

[0109] Optionally, the method The method further includes demolding (910) the composite part (714) from the lay-up mandrel (120).

[0110] Optionally, solidifying (906) the preform (170) includes heating (912) the preform (170) using a heater (122) of the lay-up mandrel (120).

[0111] Optionally, solidifying (906) the preform includes heating (912) the preform using a heater (182) of an autoclave (180).

[0112] Optionally, solidifying (906) the preform (170) includes pressurizing (914) the pressure chamber (187) using a pressure system (190). The method further includes inflating (905) a bladder (199) in the preform (170) that supports the hollow interior (170-1) of the preform (170) against compressive forces with pressure from the pressure chamber (187).

[0113] Optionally, forming (904) the pressure chamber (187) includes sealing (804) the arcuate gap (310) between the lay-up mandrel (120) and the autoclave (180). Optionally, sealing (804) the arcuate gap (310) includes forming (808) an insulating barrier.

[0114] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method (900) in any one of the preceding examples.

[0115] According to one aspect of the present disclosure, a system (100) is disclosed, comprising: an autoclave (180) including a hollow portion (189); a lay-up mandrel (120) defining a lay-up area (640) for the preform (170) and sized for insertion into a hollow (189) within the autoclave (180), thereby defining a pressure chamber (187) for consolidating the preform (170) into a composite part (714); and a sealing portion (124, 150) that bridges the gap (310) between the lay-up mandrel (120) and the autoclave (180) to close the pressure chamber (187).

[0116] Optionally, the system The system further includes an autonomous guided vehicle (AGV) (130) that drives the lay-up mandrel (120) into the hollow portion (189).

[0117] Optionally, both the lay-up mandrel (120) and the autoclave (180) include heaters (122, 182) for consolidating the preform (170) into a composite part (714).

[0118] Optionally, the system It further includes a pressure system (190) for pressurizing the pressure chamber (187).

[0119] Optionally, the heater (122, 182) includes a resistive heater (126).

[0120] Optionally, the heater (122, 182) includes a susceptor (127).

[0121] Optionally, the pressure chamber (187) is arcuate.

[0122] Optionally, the autoclave (180) forms part of the boundary (192) of the clean room environment (177).

[0123] Optionally, the lay-up mandrel (120) is arc-shaped.

[0124] Optionally, the autoclave (180) further includes a vent (183) for directing heated air into a pressure chamber (187) formed between the lay-up mandrel (120) and the autoclave (180).

[0125] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0126] According to one aspect of the present disclosure, a method (1300) for moving a preform (170) out of a clean room (177) is disclosed, the method comprising: removing (1302) the preforms (170) on the lay-up mandrels (120) from the clean room (177) and aligning them with the autoclave (180); sealing (1304) the lay-up mandrel (120) to the autoclave (180) using a peripheral seal (150); treating (1306) the preform (170) in an autoclave (180); and removing (1308) the lay-up mandrel (120) from the autoclave (180) and placing it in the non-clean room (178).

[0127] Optionally, treating (1306) the preform (170) includes curing (1310) the preform (170).

[0128] Optionally, treating (1306) the preform (170) includes pressurizing (1312) a pressure chamber (187) formed by the lay-up mandrel (120) and the autoclave (180).

[0129] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method (1300) in any one of the preceding examples.

[0130] According to one aspect of the present disclosure, a method (800) of sealing an autoclave (180) is disclosed, the method comprising: driving (802) the lay-up mandrel (120) in a process direction (179) into the autoclave (180); and sealing (804) the inlet (722) of the autoclave (180) with a seal (124) attached to the lay-up mandrel (120).

[0131] Optionally, sealing (804) the inlet (722) includes clamping (806) the seal (124) to the autoclave (180).

[0132] Optionally, the method The method further includes heating (1004) the preform (170) on the lay-up mandrel (120) with a heater (182) of the autoclave (180).

[0133] Optionally, the method The method further includes heating (1004) the preform (170) on the layup mandrel (120) by the heater (122) of the layup mandrel (120).

[0134] Optionally, the method The method further includes sealing (201) the caul plate (160) to the lay-up mandrel (120) over the preform (170).

[0135] Optionally, the layup mandrel (120) is driven (802) into the autoclave (180), thereby forming a pressure chamber (187) between the layup mandrel (120) and the autoclave (180).

[0136] Optionally, the method The method further includes driving (1108) the lay-up mandrel (120) in a process direction (179) out of the autoclave (180).

[0137] Optionally, sealing (804) the inlet (722) includes sealing (804) the arcuate gap (310) between the lay-up mandrel (120) and the autoclave (180).

[0138] Optionally, sealing (804) the inlet (722) includes forming (808) an insulating barrier.

[0139] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method (800) in any one of the preceding examples.

[0140] According to one aspect of the present disclosure, a system (100) is disclosed, the system (100) comprising: an autoclave (180) defining a cavity (189) for receiving a lay-up mandrel (120); A layup mandrel (120) defining a layup area (640) for the preform (170), the layup mandrel (120) including a sealing portion (124) that seals a gap (310) between the layup mandrel (120) and an autoclave (180).

[0141] Optionally, the seal (124) is configured to clamp the autoclave (180).

[0142] Optionally, the system The autoclave (180) is further equipped with a heater (182).

[0143] Optionally, the system The lay-up mandrel (120) is further equipped with a heater (122).

[0144] Optionally, the system A backing plate (160) is further provided to seal the preform (170) to the lay-up mandrel (120).

[0145] Optionally, the lay-up mandrel (120) and the autoclave (180) define a pressure chamber (187) for the preform (170) while the lay-up mandrel (120) is inserted into the autoclave (180).

[0146] Optionally, the seal (124) is attached to the lay-up mandrel (120) by a hinge (125).

[0147] Optionally, the sealing portion (124) forms an arcuate shape.

[0148] Optionally, the sealing portion (124) comprises a rigid segment of material.

[0149] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0150] According to one aspect of the present disclosure, a method (1000) of sealing an autoclave (180) is disclosed, the method comprising: driving (1002) the lay-up mandrel (120) in a process direction (179) into an autoclave (180); and heating (1004) the preform (170) on the lay-up mandrel (120) by a heater (122) disposed within the lay-up mandrel (120) and by a heater (182) disposed within the autoclave (180).

[0151] Optionally, heating (1004) the preform (170) includes passing current (1006) through the lay-up mandrel (120) and the resistance heater (126) in the autoclave (180).

[0152] Optionally, Heating (1004) the preform (170) includes applying (1008) an electromagnetic field to the lay-up mandrel (120) and the susceptor (127) in the autoclave (180).

[0153] Optionally, heating (1004) the preform (170) includes raising (1010) the temperature of the preform (170) to a curing temperature of the thermosetting resin in the preform (170).

[0154] Optionally, heating (1004) the preform (170) includes raising (1012) the temperature of the preform (170) to the melting temperature of the thermoplastic resin in the preform (170).

[0155] Optionally, the method The method further includes sealing (201) the caul plate (160) to the lay-up mandrel (120) over the preform (170).

[0156] Optionally, the lay-up mandrel (120) is driven (1002) into the autoclave (180), thereby forming a pressure chamber (187) between the lay-up mandrel (120) and the autoclave (180).

[0157] Optionally, the method The method further includes driving (1108) the lay-up mandrel (120) in a process direction (179) out of the autoclave (180).

[0158] Optionally, the method The method further includes sealing (804) a gap between the lay-up mandrel (120) and the autoclave (180) with an insulating barrier.

[0159] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method described in any one of the preceding examples.

[0160] According to one aspect of the present disclosure, a system (100) is disclosed, the system (100) comprising: an autoclave (180) defining a cavity (189) for receiving a lay-up mandrel (120), the autoclave (180) including a heater (122, 182); a layup mandrel (120) defining a layup area (640) for the preform (170), the layup mandrel (120) being sized for insertion into the hollow portion (189) of the autoclave (180) and including a heater (122).

[0161] Optionally, the heater (182) of the autoclave (180) and the heater (122) of the lay-up mandrel (120) include a resistance heater (126).

[0162] Optionally, the heater (182) of the autoclave (180) and the heater (122) of the lay-up mandrel (120) include a susceptor (127).

[0163] Optionally, the lay-up mandrel (120) is sized to exit the autoclave (180) by moving in the same direction (179) that the lay-up mandrel (120) was inserted into the autoclave (180).

[0164] Optionally, the system A backing plate (160) is further provided to seal the preform (170) to the lay-up mandrel (120).

[0165] Optionally, the lay-up mandrel (120) and the autoclave (180) define a pressure chamber (187) for the preform (170) while the lay-up mandrel (120) is inserted into the autoclave (180).

[0166] Optionally, the lay-up mandrel (120) is sized so that insertion of the lay-up mandrel (120) into the autoclave (180) results in a gap (310) of less than 25.4 centimeters (10 inches) between the autoclave (180) and the preform (170).

[0167] Optionally, the lay-up mandrel (120) forms the lower boundary (514) of the pressure chamber (187) of the autoclave (180) while inserted into the autoclave (180).

[0168] Optionally, while the lay-up mandrel (120) is inserted into the autoclave (180), the lay-up mandrel (120) and the autoclave (180) together form a pressure chamber (187).

[0169] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0170] According to one aspect of the present disclosure, a method (1100) of sealing an autoclave (180) is disclosed, the method comprising: driving (1102) the lay-up mandrel (120) in a process direction (179) into an autoclave (180); sealing (1104) the layup mandrel (120) to the autoclave (180) with a seal (150), thereby forming a pressure chamber (187) bounded by the layup mandrel (120) and the autoclave (180); consolidating (1106) the preform (170) on the lay-up mandrel (120) into a composite part (714); and driving (1108) the lay-up mandrel (120) in a process direction (179) out of the autoclave (180).

[0171] Optionally, driving (1102) the layup mandrel (120) is performed by an autonomous guided vehicle (AGV) (130).

[0172] Optionally, the method The method further includes demolding (1110) the composite part (714) from the lay-up mandrel (120).

[0173] Optionally, solidifying (1106) the preform (170) includes heating (912) the preform (170) using a heater (122) of the lay-up mandrel (120).

[0174] Optionally, solidifying (1106) the preform (170) includes heating (912) the preform using a heater (182) of an autoclave (180).

[0175] Optionally, the lay-up mandrel (120) is driven (1102) into the autoclave (180), thereby forming a pressure chamber (187) between the lay-up mandrel (120) and the autoclave (180).

[0176] Optionally, the layup mandrel (120) is moved out of the clean room environment (177) by driving (1102) the layup mandrel (120) in a process direction (179) out of the autoclave (180).

[0177] Optionally, sealing (1104) the lay-up mandrel (120) to the autoclave (180) includes sealing (804) an arcuate gap (310) between the lay-up mandrel (120) and the autoclave (180). Optionally, sealing (1104) the arcuate gap (310) includes forming (808) an insulating barrier.

[0178] According to one aspect of the present disclosure, a portion of an aircraft (1402) is disclosed, assembled according to the method (1100) in any one of the preceding examples.

[0179] According to one aspect of the present disclosure, a system (100) is disclosed, the system (100) comprising: An autoclave (180, 720) having an inlet (722) and an outlet (724) spaced a distance from the inlet (722) in a process direction (179, 779), the autoclave (180, 720) forming a portion of a pressure chamber (187), the pressure chamber (187) being completed by inserting a lay-up mandrel (120, 710) into the autoclave (180, 720) and sealing the lay-up mandrel (120, 710) in place.

[0180] Optionally, the system Further included is a layup mandrel (120, 710) defining a layup area (640) for the preform (170), the layup mandrel (120, 710 being dimensioned for insertion into the autoclave (180, 720) via the inlet (722) and removal from the autoclave (180, 720) via the outlet (724). Optionally, the layup mandrel (120, 710) forms a boundary (514) of a pressure chamber (187) in the autoclave (180, 720).

[0181] Optionally, the lay-up mandrel (120, 710) includes a sealing portion (124) that seals the arcuate gap (310) between the autoclave (180, 720) and the lay-up mandrel (120, 710). Optionally, the sealing portion (124) is attached to the lay-up mandrel by a hinge (125).

[0182] Optionally, the system The system further includes an autonomous guided vehicle (AGV) (130) that drives the lay-up mandrel (120, 710).

[0183] Optionally, the lay-up mandrel (120, 710) includes a heater (122) and the autoclave (180, 720) includes a heater (182) for consolidating the preform (170) into the composite part (714).

[0184] Optionally, the heater (122, 182) includes a resistive heater (126).

[0185] Optionally, the heater (122, 182) includes a susceptor (127).

[0186] Optionally, the system It further includes a pressure system (190) for pressurizing the pressure chamber (187).

[0187] Optionally, the lay-up mandrel (120, 710) is inserted into the autoclave (180, 720), thereby forming a pressure chamber (187) between the lay-up mandrel and the autoclave (180, 720).

[0188] Optionally, the autoclave (180, 720) forms the boundary (192) of the clean room environment (177).

[0189] Optionally, the lay-up mandrel (120, 710), the inlet (722), and the outlet (724) are arcuate and form complementary arcs. Optionally, the autoclave (180, 720) further includes a vent (183) for directing heated air into a pressure chamber (187) formed between the lay-up mandrel (120, 710) and the autoclave (180, 720).

[0190] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0191] According to one aspect of the present disclosure, a system (100) is disclosed, the system (100) comprising: An autoclave (180, 720), an inner surface (186) defining a hollow (189) configured to receive a lay-up mandrel (120, 710) having a preform (170) for a composite part (714), the inner surface (186) complementing the outer shape (162) of the lay-up mandrel (120, 710); an entrance (722) to a hollow portion (189); an outlet (724) of the hollow portion (189), the outlet (724) being a fixed distance from the inlet in the process direction (179, 799) of the lay-up mandrel movement; an autoclave (180, 720) comprising a heater (122, 182) for processing the preform (170) into a composite part (714); and a pressure system (190) for pressurizing a pressure chamber (187) bounded by the inner surface (186), the seals (124, 150), and the lay-up mandrel (120, 710);

[0192] Optionally, the heater (122, 182) comprises a resistive heater (126). Optionally, the heater (122, 182) comprises a susceptor (127).

[0193] Optionally, the pressure chamber (187) is arcuate.

[0194] According to one aspect of the present disclosure, manufacturing a portion of an aircraft (1402) using a system (100) as described in any one of the previous examples is disclosed.

[0195] Although specific embodiments are described herein, the scope of the disclosure is not limited to such specific embodiments, and is defined by the following claims.

Claims

1. A method (200) for consolidating a preform (170) into a composite part (714), comprising: Aligning (204) a lay-up mandrel (120) holding a preform (170) for insertion into an autoclave (180), the autoclave (180) having an inner surface (186) complementary to an outer shape (162) of the preform (170); and sealing (208) the lay-up mandrel (120) in the autoclave (180), the autoclave (180) forming a boundary (192) between a clean room environment (177) and an assembly environment (178).

2. 10. The method of claim 1, further comprising driving the layup mandrel in a process direction into the autoclave to nest the preform and the inner surface of the autoclave, wherein driving the layup mandrel into the autoclave creates a gap of less than 10 inches between the inner surface of the autoclave and the outer shape of the preform.

3. consolidating (210) the preform (170) into a composite part (714) by applying heat in the autoclave (180), wherein consolidating (210) the preform includes applying heat by a heater (122) positioned below the preform (170) in the lay-up mandrel (120); and / or 3. The method of claim 1, wherein solidifying the preform comprises applying heat via a heater disposed outside the interior surface of the autoclave.

4. 4. The method (200) of any one of claims 1 to 3, further comprising sealing (201) a caul plate (160) and / or a vacuum bag (717) to the lay-up mandrel (120) before sealing the lay-up mandrel in the autoclave (180).

5. 5. The method (200) of any one of claims 1 to 4, wherein sealing (208) the lay-up mandrel (120) in the autoclave (180) comprises sealing an arcuate gap (310) between the preform (170) and the inner surface (186) of the autoclave (180).

6. 6. The method of claim 5, wherein sealing the layup mandrel in the autoclave comprises sealing a periphery of the layup mandrel to the interior surface of the autoclave.

7. the lay-up mandrel (120) forms a lower boundary (514) of a chamber of the autoclave (180), and / or the method further comprises:

7. The method (200) of any one of claims 1 to 6, comprising disposing (200-1) on the preform (170) a bladder (199) that structurally supports a hollow interior (170-1) of the preform (170) and / or the method further comprising supporting (211) the hollow interior (170-1) of the preform (170) against compression caused by pressure applied by the autoclave (180).

8. A method (1300) for moving a preform (170) out of a clean room (177), comprising: removing (1302) the preform (170) on the lay-up mandrel (120) from the clean room (177); sealing (1304) the lay-up mandrel (120) in an autoclave (180); treating (1306) the preform (170) in the autoclave (180); and removing (1308) the lay-up mandrel (120) from the autoclave (180) into an assembly environment (178) separate from a clean room (177).

9. 10. The method of claim 8, wherein moving the preform on the layup mandrel comprises moving the layup mandrel into alignment with the autoclave.

10. 10. The method of claim 8 or 9, wherein sealing the layup mandrel to the autoclave comprises sealing a curved gap between the layup mandrel and the autoclave.

11. 11. The method (1300) of any one of claims 8 to 10, wherein sealing (1304) the lay-up mandrel (120) in the autoclave (180) forms a pressure chamber (187) in which the preform (170) is solidified.

12. An apparatus in the form of a lay-up mandrel (120), comprising: a lay-up surface (123) defining a contour (162) suitable for the preform (170); a first seal (150) that seals the lay-up mandrel (120) to the autoclave (180) when the lay-up mandrel (120) is advanced into the autoclave (180); a second sealing portion (124) that seals an arcuate gap (310) between the lay-up mandrel (120) and the autoclave (180) after the lay-up mandrel (120) is advanced into the autoclave (180).

13. 13. The apparatus of claim 12, wherein the layup mandrel further comprises a heater disposed below the layup surface for heating the preform disposed on the layup mandrel.

14. 1. A system (100) for consolidating a preform (170) into a composite part (714), comprising: An apparatus according to claim 12 or 13; an autoclave (180) sized to receive the lay-up mandrel (120) such that the lay-up mandrel (120) defines a boundary of a chamber (187) of the autoclave, the autoclave including an inner surface (186) complementary to the outer shape (162) of the lay-up mandrel (120).

15. The system of claim 14, wherein the autoclave (180) forms a boundary (192) between a clean room environment (177) and an assembly environment (178).

Images