Forming systems and methods for forming an elongate charge of composite material

A forming system configured to form an elongate charge of composite material to a predefined material shape, the forming system comprising:

• an elongate forming tool having an elongate forming surface with a forming surface shape that corresponds to the predefined material shape;
• and
• an elongate end effector, wherein the elongate end effector is configured to tension the elongate charge of composite material across the elongate forming surface, and further wherein the elongate end effector includes:
• (i) an elongate vacuum distribution manifold including a vacuum inlet, which is configured to receive an applied vacuum, and a vacuum outlet;
• (ii) a porous elongate vacuum region, which is defined by a strip of porous material and is configured to receive the applied vacuum from the vacuum outlet to generate a pressure differential that is configured to retain the elongate charge of composite material in contact with the porous elongate vacuum region;
• and
• (iii) an elongate friction surface, which is defined by a strip of friction material and extends along a length of the strip of porous material, wherein the elongate friction surface is configured to generate a frictional force that resists a sliding motion between the elongate end effector and the elongate charge of composite material, and wherein the strip of friction material is proximate a trailing edge of the elongate end effector relative to the strip of porous material;
• wherein at least one of:
• (i) a coefficient of static friction between the elongate charge of composite material and the elongate friction surface is greater than a coefficient of static friction between the elongate charge of composite material and the porous elongate vacuum region;
• and
• (ii) a coefficient of kinetic friction between the elongate charge of composite material and the elongate friction surface is greater than a coefficient of kinetic friction between the elongate charge of composite material and the porous elongate vacuum region.