Methods for Forming a Composite Blade Stiffener and Facilitating Application of Barely Visible Impact Damage Treatments

A method comprising:

• forming a cut line on a flat composite charge having opposing 45 degree beveled edges angled outward from the cut line;
• positioning the flat composite charge centered about a tooling plunger such that the tooling plunger is aligned with the cut line;
• and
• activating the tooling plunger to move downward and fold the flat composite charge at the cut line into a cavity of a forming mandrel, wherein after moving the tooling plunger downward and folding the flat composite charge, the opposing 45 degree beveled edges form a substantially flat surface perpendicular to the cut line.

A method for forming a flat composite charge into a composite blade stiffener, comprising:

• cutting the flat composite charge along a cut line into two pieces separated by edges that are angled outward from the cut line;
• positioning the flat composite charge on a forming mandrel about a tooling plunger such that the tooling plunger is aligned with the cut line;
• and
• activating the tooling plunger to drive the two pieces of the flat composite charge into a cavity of the forming mandrel resulting in the edges forming a substantially flat surface perpendicular to the cut line and a first flange and a second flange connected to the substantially flat surface.