Composite structure fabrication systems and methods

A composite structure fabrication system, comprising:

• a plurality of ply carriers, wherein each ply carrier of the plurality of ply carriers defines a ply support surface configured to temporarily support at least one ply segment;
• an elongate forming mandrel that defines an elongate ply forming surface, wherein the elongate ply forming surface is shaped to define a surface contour of a composite structure and is configured to receive a plurality of ply segments to define a plurality of plies of composite material that at least partially defines the composite structure;
• a carrier transfer device;
• a forming machine;
• and
• a controller programmed to control operation of the carrier transfer device and the forming machine to:
• (i) selectively convey, with the carrier transfer device, a selected ply carrier of the plurality of ply carriers from a ply kitting area to an intermediate location;
• (ii) transfer the selected ply carrier to the forming machine at the intermediate location;
• (iii) translate the forming machine along a length of the elongate forming mandrel to a selected location along the length of the elongate forming mandrel;
• (iv) deform, with the forming machine, the selected ply carrier and a respective ply segment, which is supported by the selected ply carrier, over a selected portion of the elongate ply forming surface;
• (v) release the respective ply segment from the selected ply carrier while retaining the respective ply segment on the selected portion of the elongate ply forming surface;
• and
• (vi) return, with the forming machine, the selected ply carrier to the carrier transfer device.