Expandable Pallet Composite Forming System

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Solution Overview

Problem

Existing methods for forming composite stringers in aircraft are inefficient, requiring pre-forming with vertical punch style operations, unique forming tools for each part, and multiple passes to build up a full laminate, which limits production speed and efficiency.

Innovation Solution

A method and system using an expandable pallet and a series of rollers to shape and form a laminated charge into a composite structure along a continuously moving manufacturing line, allowing for progressive urging of the charge into a continuously expanding recess to achieve the desired shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pre-forming with vertical punch style operations is used, then the composite structure can be formed, but the cycle time increases and production speed is limited

Engineering Contradiction:

Improvecomposite structure formationVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The forming tool is transformed from a static vertical punch system to a dynamic system where the tool moves horizontally along a continuous path, enabling continuous production while maintaining forming precision through controlled motion

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The forming process transitions from discrete batch operations to a continuous horizontal forming action, where the laminated charge is continuously fed and formed as the tool moves along the production line, eliminating idle cycle times

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If a unique forming tool is used for each part, then the composite structure can be formed with precision, but the device complexity increases due to frequent tooling changes

Engineering Contradiction:

Improvepart formation accuracyVSAvoidtooling change requirements

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

A single horizontal forming tool is designed to perform multiple forming operations for different composite structure parts by adjusting its position and parameters along the continuous path, eliminating the need for multiple unique tools and frequent tooling changes

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If multiple passes are used to build up a full laminate, then the composite structure can be formed, but the manufacturing time increases

Engineering Contradiction:

Improvelaminate constructionVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The complete laminated charge is prepared and positioned in advance on the forming tool before the horizontal forming action begins, allowing all laminate layers to be formed in a single continuous pass rather than requiring multiple sequential passes to build up the structure

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12311618B2Methods, devices, and systems for forming a composite structure using an expandable pallet

Publication Date: 2025.05.27 THE BOEING CO

AI summary

An example method of forming a composite structure includes applying a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion relative to a plurality of rollers, and progressively urging the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a serial configuration so as to shape the laminated charge into at least part of a shape of the composite structure.