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:

• a standoff;
• a tray coupled to said standoff, said tray is rotatable, between a first operating position and a second operating position, about a pivot line defined between said tray and said standoff, wherein said tray is configured to support a flange portion of the at least one layer of composite material when said tray is in the first operating position and is configured to rotate from the first operating position to the second operating position when a first force is induced against said tray, wherein the flange portion is configured to be withdrawn from said tray when said tray is rotated to the second operating position;
• and
• a pneumatic actuator extending between said standoff and said tray, said pneumatic actuator configured to provide a second force that opposes the first force to control a rate of rotation of said tray from the first operating position to the second operating position.

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

• providing a flange forming device including a standoff, a tray coupled to the standoff, and a pneumatic actuator extending between the standoff and the tray, wherein the tray is configured to rotate between a first operating position and a second operating position;
• extending at least one layer of composite material over an upper forming surface of a forming tool;
• positioning a flange portion of the at least one layer of composite material on the tray when the tray is in the first operating position in which the tray is coplanarly aligned with the upper forming surface;
• extending a pressurized bladder over the forming tool and the tray;
• inducing, with the pressurized bladder, a first force against the tray such that the tray rotates about a pivot line from the first operating position to the second operating position in which the tray is misaligned from the upper forming surface, and such that the flange portion is withdrawn from the tray and draped over at least one side forming surface of the forming tool;
• and
• controlling, with the pneumatic actuator, a rate of rotation of the tray from the first operating position to the second operating position.