Systems and methods for forming composite workpieces

A system for forming a workpiece comprising a composite material, the system comprising:

• a housing;
• a forming tool disposed in the housing;
• a plurality of actuators disposed in the housing;
• a shaping assembly comprising a lower diaphragm and an upper diaphragm;
• a negative pressure source in fluid communication with the housing;
• a vacuum gripper coupled to a first one of the actuators;
• and
• a support coupled to a second one of the actuators,
• wherein:
• the workpiece is disposed between the lower diaphragm and the upper diaphragm of the shaping assembly;
• the shaping assembly is coupled to the housing over the forming tool such that the housing and the shaping assembly form a sealed vessel around the forming tool;
• the negative pressure source creates a negative pressure between the housing and the shaping assembly to urge the shaping assembly against the forming tool;
• and
• each one of the actuators selectively extends or retracts to engage an associated one of the vacuum gripper and the support and control a shape of at least a portion of the shaping assembly while the shaping assembly is urged against the forming tool.

A method for forming a workpiece comprising a thermoformable material, the method comprising:

• forming a shaping assembly comprising a lower diaphragm, an upper diaphragm, and the workpiece disposed between the lower diaphragm and the upper diaphragm;
• coupling the shaping assembly is to a housing over a forming tool such that the housing and the shaping assembly form a sealed vessel around the forming tool;
• creating a negative pressure between the housing and the shaping assembly to urge the shaping assembly against the forming tool;
• and
• selectively extending or retracting an actuator, disposed within the housing, to engage a vacuum gripper, coupled to the actuator, and control a shape of at least a portion of the shaping assembly while the shaping assembly is urged against the forming tool.