# US 12,179,440 B2 · Systems and methods for shaping composite structures > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,179,440 B2 - Document ID: US12179440B2 - Status: Granted - Kind: B2 - Application number: 18/045,257 - Filed: 2022-10-10 - Published: 2024-04-11 - Granted: 2024-12-31 - Earliest claimed: 2022-10-10 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Luis F. Velasquez; Edward R. Duncan - Web page: https://patentgrep.com/patent/US12179440B2 ## CPC - B29C 70/38: Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} - B29D 99/0003: {Producing profiled members, e.g. beams} - B29C 53/083: {bending longitudinally, i.e. modifying the curvature of the tube axis} - B29C 70/56: Tensioning reinforcements before or during shaping - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) ## Abstract A method for shaping a composite structure includes steps of: (1) holding a composite member in an initial contour along a length of the composite member; and (2) forming a final contour along the length of the composite member by: (3) sequentially shaping formed portions of the composite member while holding unformed portions of the composite member in the initial contour to form portions of the final contour; and (4) sequentially shaping the unformed portions of the composite member to form other portions of the final contour. ## Claims ### Claim 1 A method for shaping a composite structure, the method comprising steps of: holding a composite member in an initial contour along a length of the composite member, wherein the composite member comprises a nonplanar cross-sectional shape, viewed along a longitudinal axis of the composite member; forming a final contour along the length of the composite member by: placing a first portion of the composite member at a first contact point on a place-tool surface of a place tool while holding the composite member in the initial contour; sequentially shaping unformed portions of the composite member into formed portions at sequentially located contact points along the place-tool surface of the place tool while holding remaining unformed portions of the composite member in the initial contour; and sequentially shaping the remaining unformed portions of the composite member at sequentially located subsequent contact points along the place-tool surface of the place tool; and maintaining the nonplanar cross-sectional shape of the composite member while forming the final contour by receiving at least a portion of the nonplanar cross-sectional shape of the composite member in a recess formed in the place-tool surface. ### Claim 2 (depends on 1) The method of claim 1, further comprising selectively applying tension along at least a portion of the length of the composite member while forming the final contour along the length of the composite member. ### Claim 3 (depends on 2) The method of claim 2, further comprising varying the tension applied to at least a portion of the length of the composite member while forming the final contour along the length of the composite member. ### Claim 4 (depends on 1) The method of claim 1, wherein more than one of the unformed portions are concurrently shaped into the formed portions. ### Claim 5 (depends on 1) The method of claim 1, wherein each one of the unformed portions is consecutively shaped into one of the formed portions. ### Claim 6 (depends on 1) The method of claim 1, further comprising applying heat to the composite member while forming the final contour along the length of the composite member. ### Claim 7 (depends on 1) The method of claim 1, further comprising compacting the composite member after forming the final contour along the length of the composite member. ### Claim 8 (depends on 1) The method of claim 1, further comprising: detecting a location of the composite member relative to the place tool; and adjusting the composite member relative to the place tool based on the location detected. ### Claim 9 A system for forming a composite structure, the system comprising: a plurality of automated manipulators configured to manipulate a composite member, wherein the composite member comprises a nonplanar cross-sectional shape, viewed along a longitudinal axis of the composite member; a place tool comprising a place-tool surface having a contour that defines a final contour of the composite structure and comprising a recess configured to receive at least a portion of the nonplanar cross-sectional shape of the composite member; and a controller configured to execute instructions, wherein execution of the instructions causes the controller to perform operations using the automated manipulators, the operations comprising: holding the composite member in an initial contour along a length of the composite member; placing a first portion of the composite member on at a first contact point on the place-tool surface of the place tool while holding the composite member in the initial contour; and forming a final contour along the length of the composite member while placing the composite member on the place tool by: sequentially shaping unformed portions of the composite member into formed portions at sequentially located contact points along the place-tool surface of the place tool while holding remaining unformed portions of the composite member in the initial contour; and sequentially shaping the remaining unformed portions of the composite member at sequentially located subsequent contact points along the place-tool surface of the place tool, wherein the nonplanar cross-sectional shape of the composite member is maintained while forming the final contour by receiving at least a portion of the nonplanar cross-sectional shape of the composite member in the recess formed in the place-tool surface. ### Claim 10 (depends on 9) The system of claim 9, wherein the operations further comprise selectively applying tension along at least a portion of length of the composite member while forming the final contour along the length of the composite member. ### Claim 11 (depends on 9) The system of claim 9, wherein: each one of the automated manipulators comprises a gripper; and the gripper is configured to selectively hold or release the composite member. ### Claim 12 (depends on 11) The system of claim 11, wherein: each one of the automated manipulators comprises a compactor; and the operations further comprise compacting the composite member after forming the final contour along the length of the composite member. ### Claim 13 (depends on 12) The system of claim 12, wherein: each one of the automated manipulators comprises a heater; and the operations further comprise applying heat to the composite member while forming the final contour along the length of the composite member. ### Claim 14 (depends on 13) The system of claim 13, wherein: each one of the automated manipulators comprises an end effector; and the gripper, the compactor, and the heater are integrated into the end effector. ### Claim 15 (depends on 9) The system of claim 9, further comprising a sensor configured to detect a location of the composite member relative to the place tool, wherein the operations further comprise: locating at least a portion of the composite member relative to the place tool before placing the composite member on the place tool; and adjusting the composite member relative to the place tool based on a location detected by the sensor. ### Claim 16 An automated method for shaping a composite structure, the automated method comprising steps of: using a plurality of automated manipulators to hold a composite member in an initial contour along a length of the composite member, wherein the composite member comprises a nonplanar cross-sectional shape, viewed along a longitudinal axis of the composite member; and synchronizing motion of the automated manipulators to form a final contour along the length of the composite member, wherein the final contour is formed by: placing a first portion of the composite member at a first contact point on a place-tool surface of a place tool while holding the composite member in the initial contour; sequentially shaping unformed portions of the composite member into formed portions at sequentially located contact points along the place-tool surface of the place tool while holding remaining unformed portions of the composite member in the initial contour; sequentially shaping the remaining unformed portions of the composite member at sequentially located subsequent contact points along the place-tool surface of the place tool; and maintaining the nonplanar cross-sectional shape of the composite member while forming the final contour by receiving at least a portion of the nonplanar cross-sectional shape of the composite member in a recess formed in the place-tool surface. ### Claim 17 (depends on 16) The automated method of claim 16, further comprising moving at least one of the automated manipulators relative to at least another one of the automated manipulators to apply tension along at least a portion of the length of the composite member while forming the final contour along the length of the composite member. ### Claim 18 (depends on 16) The automated method of claim 16, further comprising using a heater of at least one of the automated manipulators to apply heat to the composite member while forming the final contour along the length of the composite member. ### Claim 19 (depends on 16) The automated method of claim 16, further comprising using a compactor of at least one of the automated manipulators to compact the composite member after forming the final contour along the length of the composite member. ### Claim 20 (depends on 16) The automated method of claim 16, further comprising: using a sensor to detect a location of the composite member relative to the place tool; locating at least a portion of the composite member relative to the place tool before placing the composite member on the place tool; and adjusting the composite member relative to the place tool based on the location detected by the sensor.