Method and system for manufacturing a composite component

A system for manufacturing a composite component having a main body and a flange integral with the main body, the system comprising:

• a tool having a longitudinal axis and a transverse axis that is perpendicular to the longitudinal axis, wherein the tool is switchable between a deposition configuration and a flange-forming configuration, the tool comprising:
• a first portion comprising a first deposition surface extending along the longitudinal axis;
• a second portion that is movable relative to the first portion, the second portion comprising:
• a second deposition surface extending along the longitudinal axis;
• and
• a pre-form support surface extending along the transverse axis;
• and
• a flange-forming block connected to the second portion, the flange-forming block comprising a curved surface;
• and
• a deposition device configured to deposit a composite material at least partially on the first deposition surface and the second deposition surface in the deposition configuration of the tool;
• wherein, in the deposition configuration:
• the second deposition surface is aligned with the first deposition surface with respect to the longitudinal axis;
• the pre-form support surface is disposed adjacent to the first portion;
• and
• the flange-forming block is spaced apart from the first deposition surface with respect to the transverse axis;
• wherein the deposition device deposits the composite material at least partially on each of the first deposition surface of the first portion and the second deposition surface of the second portion in the deposition configuration of the tool to provide a composite pre-form having a first region corresponding to the main body of the composite component and a second region corresponding to the flange of the composite component;
• wherein the second portion is moved relative to the first portion to transition the tool from the deposition configuration to the flange-forming configuration, wherein, in the flange-forming configuration:
• the second deposition surface is spaced apart from the first deposition surface with respect to the transverse axis;
• the pre-form support surface is spaced apart from the first portion with respect to the longitudinal axis;
• and
• the flange-forming block is disposed between the first portion and the second portion with respect to the longitudinal axis, such that the curved surface of the flange-forming block is at least partially aligned with the first deposition surface;
• and
• wherein the transition of the tool from the deposition configuration to the flange-forming configuration causes the second region of the composite pre-form to slide relative to the second deposition surface along the longitudinal axis and at least partially engage each of the pre-form support surface of the second portion and the curved surface of the flange-forming block, and wherein the curved surface of the flange-forming block defines a radius of the flange of the composite component.