System and method for fabricating a composite structure

A system for fabricating a composite structure, the system comprising:

• a ply carrier comprising a ply support surface;
• a carrier transfer device configured to support the ply carrier;
• a lamination system;
• a transfer system in sequential relation to the lamination system;
• a forming system in sequential relation to the transfer system;
• and
• a controller programmed to:
• selectively convey the ply carrier to the lamination system using the carrier transfer device;
• selectively apply at least on composite ply to the ply support surface of the ply carrier using the lamination system;
• selectively convey the ply carrier from the lamination system to the transfer system using the carrier transfer device;
• remove the ply carrier from the carrier transfer device and apply the at least one composite ply to at least a portion of a forming surface of a forming tool using the transfer system;
• and
• form the at least one composite ply over the at least a portion of the forming surface of the forming tool using the forming system.

A method of fabricating a composite structure, the method comprising steps of:

• conveying a ply carrier to a lamination system using a carrier transfer device;
• selectively applying at least one composite ply to a ply support surface of the ply carrier using the lamination system;
• conveying the ply carrier from the lamination system to a transfer system using the carrier transfer device;
• removing the ply carrier from the carrier transfer device and applying the at least one composite ply to at least a portion of a forming surface of a forming tool using the transfer system;
• and
• forming the at least one composite ply over the at least a portion of the forming surface of the forming tool using a forming system.