Apparatus and method of forming a composite structure

A flange forming device for use in forming a composite structure from at least one layer of composite material, said device comprising:

• an upper plate;
• a lower plate;
• a biasing device extending from said upper plate;
• a compression plate coupled at a free end of said biasing device;
• and
• a receiving slot defined between said compression plate and said lower plate, said receiving slot for receiving a flange portion of the at least one layer of composite material;
• wherein said upper plate and said lower plate are hingeably coupled, and rotatable relative, to each other such that said flange forming device is selectively positioned between an open position and a closed position;
• and
• wherein said biasing device is configured to bias said compression plate towards said lower plate and bias against the flange portion with a predetermined retaining force that enables the flange portion of the at least one layer of composite material to be withdrawn from said receiving slot when the forming device is in the closed portion and translates relative to a forming tool.

A method of forming a composite structure, said method comprising:

• providing a forming tool comprising an upper forming surface and at least one side forming surface that extends from said upper forming surface;
• providing a flange forming device comprising an upper plate, a lower plate hingeably coupled to the upper plate, a biasing device extending from said upper plate, a compression plate coupled at a free end of said biasing device, and a receiving slot defined between said compression plate and said lower plate;
• extending at least one layer of composite material over the upper forming surface of the forming tool;
• positioning a flange portion of the at least one layer of composite material within the receiving slot;
• rotating the upper plate towards the lower plate such that said flange forming device moves from an open position to a closed position;
• biasing the compression plate towards said lower plate using the biasing device to retain the flange portion in the receiving slot with a predetermined retaining force,
• extending a pressurized bladder over the forming tool and the upper plate of the flange forming device;
• and
• translating the flange forming device relative to the forming tool such that the flange portion of the at least one layer of composite material is withdrawn from the receiving slot and draped over said at least one side forming surface of the forming tool, wherein the pressurized bladder is configured to force the flange portion against the at least one side forming surface as the flange forming device translates relative to the forming tool.