Apparatuses, tacking sticks, and systems for tacking workpieces in composite manufacturing and methods associated therewith

1 . An apparatus for tacking workpieces in composite manufacturing, the apparatus comprising:

a base member;

a shape memory member at least partially secured to the base member; and

heater member disposed on at least one of the base member and the shape memory member and configured to selectively radiate heat toward the shape memory member,

wherein the shape memory member is configured to transform from an inactive position to an active position in response to the heat from the heater member,

wherein the apparatus is configured to be disposed such that the active position of the shape memory member is proximate to a work surface of a first workpiece of a stack of workpieces, and

wherein the apparatus is configured to locally tack the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to the heat from the heater member and the shape memory member being in contact with the work surface of the first workpiece in the active position.

2 . The apparatus of claim 1 , wherein the shape memory member comprises a shape memory alloy.

3 . The apparatus of claim 2 , wherein the shape memory alloy comprises at least one of aluminium, cadmium, copper, gold, iron, manganese, nickel, silicon, titanium, and zinc.

4 . The apparatus of claim 2 , wherein the shape memory alloy comprises at least one of nickel-titanium, copper-aluminum-nickel, copper-zinc-aluminum, iron-manganese-silicon, and gold-cadmium.

5 . The apparatus of claim 1 , wherein the shape memory member is configured to transform to the active position in response to the heat reaching a predetermined temperature.

6 . The apparatus of claim 1 , wherein the apparatus is configured to be embedded in a support structure comprising a contact surface, wherein the apparatus is configured to extend through the contact surface of the support structure.

7 . The apparatus of claim 6 , wherein the contact surface of the support structure opposes the work surface of the first workpiece, wherein the contact surface is configured to engage with the work surface.

8 . The apparatus of claim 1 , wherein the apparatus is configured to locally tack the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to the heater member being disposed proximate to the work surface of the first workpiece while the shape memory member is in the active position.

9 . The apparatus of claim 1 , wherein the apparatus is configured to locally tack the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to the shape memory member contacting the work surface of the first workpiece while the shape memory member is in the active position.

10 . The apparatus of claim 1 , wherein the apparatus is configured to locally compress the stack of workpieces in response to the shape memory member contacting the work surface of the first workpiece while the shape memory member is in the active position.

11 . The apparatus of claim 1 , wherein the apparatus is configured to locally compact the stack of workpieces in response to the shape memory member contacting the work surface of the first workpiece while the shape memory member is in the active position.

12 . The apparatus of claim 1 , wherein the apparatus is configured to transform the shape memory member from the active position to the inactive position using at least one of a biasing spring, a shape memory effect associated with the shape memory member, a second shape memory member, and an insert fitted for compression of the shape memory member.

13 . The apparatus of claim 1 , wherein the base member comprises an insulating material.

14 . The apparatus of claim 1 , wherein the shape memory member comprises a first surface facing the base member and a second surface configured to face a work surface of a first workpiece of a stack of workpieces.

15 . The apparatus of claim 14 , wherein the heater member is secured to the first surface of the shape memory member.

16 . The apparatus of claim 14 , wherein the heater member is secured to the second surface of the shape memory member.

17 . The apparatus of claim 1 , wherein the heater member is embedded within the shape memory member.

18 . The apparatus of claim 1 , wherein the heater member comprises a packaged heat source and at least two leads, wherein the packaged heat source is less than 3 mm in height with a planar area of less than 30 mm2.

19 . The apparatus of claim 1 , wherein the heater member comprises at least one of a micro heater, a thick film heater, and a resistive heating element.

20 . The apparatus of claim 1 , wherein the heater member is configured to receive electrical power from an external power source.

21 . A tacking stick for tacking workpieces in composite manufacturing, the tacking stick comprising:

a support structure comprising a contact surface opposing a work surface of a first workpiece of a stack of workpieces, wherein the contact surface of the support structure is configured to engage with the work surface of the first workpiece; and

a plurality of tacking elements embedded in the support structure, wherein each tacking element extends through the contact surface of the support structure, each tacking element comprising:

a base member;

a shape memory member at least partially secured to the base member; and

a heater member disposed on at least one of the base member and the shape memory member, and

wherein the plurality of tacking elements are configured to be disposed within the support structure such that the active position of the shape memory member of each tacking element is proximate to a work surface of a first workpiece of a stack of workpieces, and

wherein the tacking stick is configured such that at least one of the plurality of tacking elements locally tacks the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to the shape memory member of the corresponding tacking element being in contact with the work surface of the first workpiece in the active position.

22 . A method for tacking workpieces in composite manufacturing, the method comprising:

selectively heating a heater member of a tacking element;

transforming a shape memory member from an inactive position to an active position; and

locally tacking a first workpiece of a stack of workpieces to at least an adjacent workpiece of the stack of workpieces while the shape memory member is in the active position, and

wherein, in response to the heating and the transforming, the active position causes the shape memory member to become proximate to a work surface of the first workpiece of the stack of workpieces, and

wherein, in conjunction with the tacking, the shape memory member is in the active position and in contact with the work surface of the first workpiece.

23 . A system for tacking workpieces in composite manufacturing, the system comprising:

an end effector comprising a tacking stick, the tacking stick comprising:

a support structure comprising a contact surface; and

a plurality of tacking elements embedded in the support structure, wherein the plurality of tacking elements extend through the contact surface of the support structure,

wherein each tacking element comprises:

a base member;

a shape memory member at least partially secured to the base member; and

a heater member disposed on at least one of the base member and the shape memory member;

a mechanical arm configured to receive the end effector; and

a computerized control system configured to control the mechanical arm, the end effector, the tacking stick, and the plurality of tacking elements by implementing a method for tacking workpieces in composite manufacturing, the method comprising:

selectively heating the heater member of a select tacking element;

transforming the shape memory member of the select tacking element from an inactive position to an active position; and

locally tacking a first workpiece of a stack of workpieces to at least an adjacent workpiece of the stack of workpieces while the shape memory member of the select tacking element is in the active position, and

wherein the plurality of tacking elements are configured to be disposed within the support structure such that the active position of the shape memory member of each tacking element is proximate to a work surface of a first workpiece of a stack of workpieces, and

wherein the system is configured such that at least one of the plurality of tacking elements locally tacks the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to the shape memory member of the corresponding tacking element being in contact with the work surface of the first workpiece in the active position.

24 . The system of claim 23 , wherein each tacking element of the plurality of tacking elements is configured to locally tack the first workpiece to at least an adjacent workpiece of the stack of workpieces in response to at least one of the shape memory member and the heater member being disposed proximate to the work surface of the first workpiece while the shape memory member is in the active position.