Method for making contoured composite stiffeners

1. A method of making a compound contoured composite blade stringer for aircraft, comprising:

placing a resin distribution media on an assembly tool;

placing a preform on the assembly tool covering the resin distribution media to form a preform charge;

aligning the resin distribution media and the preform charge relative to each other and along an alignment guide having a first contour;

placing a blade height spacer over the preform charge;

clamping a flange portion of the charge to maintain the alignment of the charge, including using the blade height spacer to control placement of clamps on the charge, to form a clamped charge;

installing an inner vacuum bag over a forming tool;

applying a first vacuum to a forming tool side of the inner vacuum bag

transferring the clamped charge to the forming tool;

clamping a web portion of the charge in the forming tool, including inflating a bladder and using the inflation of the bladder to move a pair of mandrels into clamping engagement with the charge;

removing the clamps from the flange portion of the charge while the web portion of the charge is clamped between the mandrels;

forming a formed charge including a pair of stringer flanges by folding the flange portion of the charge down onto the mandrels;

folding the inner vacuum bag back over the formed charge;

placing an outer vacuum bag over the inner vacuum bag covering the formed charge;

sealing the inner and outer bags;

applying second and third vacuums respectively to the inner vacuum bag and the outer vacuum bag;

infusing the preform with resin by introducing resin into the inner vacuum bag to form a resin infused fiber preform;

curing the resin infused fiber preform on the forming tool to form a cured stringer; and

removing the cured stringer from the forming tool following curing.