Patent Publication Number: US-10780614-B2

Title: System and method for forming stacked materials

Description:
BACKGROUND 
     The field of the disclosure relates generally to systems for forming stacked materials and, more particularly, to systems that include membranes to facilitate forming stacked materials. 
     At least some known systems are used to form stacked materials into composite laminate components. The stacked materials include a plurality of layers or plies of composite material that provide the composite laminate component with improved engineering properties. For example, the stacked materials include layers of any of the following materials: prepregs, dry fabrics, carbon fabrics, tackified fabrics, release films, backing paper, vacuum films, liners, membranes, carbon fiber, glass, polymeric fibers such as polyimides and polyethylenes, ceramic matrix composites, silicon carbide, and alumina. In at least some systems, the stacked material is positioned adjacent to a tool and forced against the tool to shape the stacked material into the component shape. In some systems, a membrane is used to facilitate shaping the stacked material. The membrane is extended over the stacked material and/or tool and positioned in a controlled manner to cause the tool to shape the stacked material. 
     In at least some known systems, the tool has complex geometries, such as overhangs, undercuts, concave surfaces, and convex surfaces. However, the membrane bridges over these complex geometries and does not cause the stacked material to be adequately compacted. As a result, the stacked material is not properly formed adjacent to these complex geometries. Therefore, additional processing, such as debulking, is required to properly form the stacked material into the desired component. 
     BRIEF DESCRIPTION 
     In one aspect, a system for forming stacked material is provided. The system includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall. 
     In another aspect, a system for forming stacked material is provided. The system includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one insert is in the interior space. 
     In yet another aspect, a method of forming stacked material is provided. The method includes coupling the stacked material to a tool disposed in an interior space of a housing and moving a membrane towards the tool in the interior space of the housing. The stacked material is shaped using the tool. The method further includes moving an intensifier mechanism such that the stacked material is compressed at predetermined locations. 
    
    
     
       DRAWINGS 
       These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is a side view of an exemplary system for forming stacked material including an intensifier mechanism; 
         FIG. 2  is a plan view of the intensifier mechanism of the system shown in  FIG. 1 ; 
         FIG. 3  is a schematic diagram of a sequence for forming stacked materials using an exemplary system including an intensifier mechanism positioned on the stacked materials; 
         FIG. 4  is a side view of an exemplary system for forming stacked material; 
         FIG. 5  is a plan view of the system shown in  FIG. 4 ; 
         FIG. 6  is a schematic diagram of a sequence for forming stacked material using a first configuration of the system shown in  FIG. 4 ; 
         FIG. 7  is a schematic diagram of a sequence for forming stacked material using a second configuration of the system shown in  FIG. 4 ; 
         FIG. 8  is a side view of the system shown in  FIG. 4  including a first set of inserts; 
         FIG. 9  is a side view of the system shown in  FIG. 4  including a second set of inserts; 
         FIG. 10  is a side view of the system shown in  FIG. 4  including a third set of inserts; 
         FIG. 11  is a schematic diagram of forming a plurality of stacked materials onto a plurality of tools using the system shown in  FIG. 4 ; 
         FIG. 12  is a plan view of a plurality of the systems shown in  FIG. 4  configured for forming a plurality of stacked materials onto a plurality of tools; 
         FIG. 13  is schematic diagram of a sequence for forming stacked material using an exemplary system including intensifier mechanisms; 
         FIG. 14  is a schematic plan view of a sequence for forming stacked material using the system shown in  FIG. 13 ; and 
         FIG. 15  is a schematic diagram of a sequence for forming stacked materials using an exemplary system including intensifier mechanisms. 
     
    
    
     Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein. 
     DETAILED DESCRIPTION 
     In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings. 
     The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. 
     “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. 
     Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “substantially,” and “approximately,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. 
     As used herein, the terms “processor” and “computer,” and related terms, e.g., “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, a programmable logic controller (PLC), and application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, memory may include, but it not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc—read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a mouse and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the exemplary embodiment, additional output channels may include, but not be limited to, an operator interface monitor. 
     Further, as used herein, the terms “software” and “firmware” are interchangeable, and include any computer program storage in memory for execution by personal computers, workstations, clients, and servers. 
     As used herein, the term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method of technology for short-term and long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, the methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer-readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including without limitation, volatile and non-volatile media, and removable and non-removable media such as firmware, physical and virtual storage, CD-ROMS, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being transitory, propagating signal. 
     The systems described herein include a membrane to facilitate forming stacked material into a component. The system includes a housing defining an interior space and a tool disposed in the interior space. The membrane is moved in the interior space towards the tool. In some embodiments, at least one insert is disposed in the interior space to control movement of the membrane, reduce stretching of the membrane, and provide a controlled movement of the membrane. In further embodiments, at least one intensifier mechanism is disposed in the interior space to facilitate shaping the stacked material with the tool. The at least one intensifier mechanism is configured to cause the tool to shape the component into complex geometries. In some embodiments, the at least one intensifier mechanism provides contact pressure between the stacked material and the tool for increased compaction of the stacked material. 
       FIG. 1  is a side view of a system  10  for forming stacked material  12  including an intensifier mechanism  14 .  FIG. 1  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description.  FIG. 2  is a plan view of intensifier mechanism  14 . System  10  includes intensifier mechanism  14 , a housing  16 , a tool  18 , a membrane  20 , and inserts  22 . Housing  16  includes a bottom wall  24 , a side wall  26  coupled to bottom wall  24 , and a perforated plate  28  disposed on bottom wall  24 . Housing  16  defines an interior space  30 . In alternative embodiments, system  10  has any configuration that enables system  10  to operate as described herein. For example, in some embodiments, tool  18 , inserts  22 , and/or housing  16  are integrally formed. 
     In the exemplary embodiment, stacked material  12  includes a plurality of layers or plies of composite material. In alternative embodiments, stacked material  12  includes any layers that enable system  10  to operate as described herein. For example, in some embodiments, stacked material  12  includes layers of any of the following materials, without limitation: prepregs, dry fabrics, carbon fabrics, tackified fabrics, release films, backing paper, vacuum films, liners, membranes, carbon fiber, glass, polymeric fibers such as polyimides and polyethylenes, ceramic matrix composites, silicon carbide, and alumina. 
     During operation of system  10 , a negative pressure is generated in interior space  30  such that membrane  20  is drawn towards bottom wall  24 . As membrane  20  moves towards bottom wall  24 , membrane  20  contacts stacked material  12 , tool  18 , side wall  26 , inserts  22 , and intensifier mechanism  14 . Intensifier mechanism  14  is positioned on stacked material  12  adjacent tool  18  such that intensifier mechanism  14  induces a force in stacked material  12  as membrane  20  moves towards bottom wall  24 . Intensifier mechanism  14  is configured to move in directions along the X-axis, Z-axis, and Y-axis such that intensifier mechanism  14  contacts stacked material  12  at predetermined locations. In particular, intensifier mechanism  14  induces a force against portions of stacked material  12  adjacent complex geometries on tool  18  to facilitate tool  18  shaping stacked material  12 . 
     In some embodiments, intensifier mechanism  14  is coupled to stacked material  12  at fixed positions. In other embodiments, intensifier mechanism  14  is loosely positioned on stacked material  12 . In alternative embodiments, intensifier mechanism  14  is coupled to any of housing  16 , tool  18 , and membrane  20 . For example, in some embodiments, intensifier mechanism  14  extends beyond stacked material  12  and couples to tool  18 . In further embodiments, at least a portion of intensifier mechanism  14  is fixed to tool  18 . In still further embodiments, intensifier mechanism  14  is integral with tool  18 . In some embodiments, intensifier mechanism  14  is removably coupled to tool  18 . 
     In the exemplary embodiment, intensifier mechanism  14  is disposed in interior space  30  and includes bodies  32  and support  34 . Each body  32  has a shape that corresponds to a desired shape of a component formed from stacked material  12  and engages a portion of tool  18 . Support  34  extends between bodies  32  and is coupled to bodies  32  such that bodies  32  are movable in relation to housing  16 . In particular, bodies  32  and support  34  are movably coupled together such that at least a portion of bodies  32  pivots about support  34 . Accordingly, support  34  forms a hinge. In some embodiments, each support  34  and/or bodies  32  includes any number of segments, including one, that enable system  10  to operate as described herein. In the exemplary embodiment, support  34  includes two segments coupled to bodies  32  at positions that facilitate bodies  32  inducing forces in stacked material  12  at precise locations. In further embodiments, support  34  includes a plurality of segments extending between the same bodies  32 . In some embodiments, support  34  extends the full length of intensifier mechanism  14 . In alternative embodiments, intensifier mechanism  14  has any configuration that enables system  10  to operate as described herein. For example, in some embodiments, intensifier mechanism  14  is formed as a single integrated component. In further embodiments, intensifier mechanism  14  includes at least one body  32  embedded in support  34 . In still further embodiments, intensifier mechanism  14  includes at least one body  32  and support  34  is omitted. 
     Also, in the exemplary embodiment, intensifier mechanism  14  is made from materials that facilitate the positioning of intensifier mechanism  14  during operation of system  10 . For example, support  34  is made from a material that is flexible to enable bodies  32  to move and has some rigidity to maintain proper positioning of intensifier mechanism  14  in relation to stacked material  12 . Bodies  32  are substantially rigid to retain shape during positioning. Moreover, intensifier mechanism  14  is made from materials that withstand relatively high temperatures. For example, support  34  and bodies  32  remain sufficiently rigid to retain their shape when system  10  is heated. In alternative embodiments, intensifier mechanism  14  is made of any materials that enable system  10  to operate as described herein. For example, in some embodiments, intensifier mechanism  14  is made from materials that are compatible with stacked material  12 , e.g., materials that do not contaminate stacked material  12  when intensifier mechanism  14  directly contacts stacked material  12 . In further embodiments, bodies  32  are made from semi-rigid materials. For example, in some embodiments, bodies  32  include any of the following materials: silicone, rubber, semi-rigid plastic, and combinations thereof. 
     In addition, in the exemplary embodiment, system  10  further includes a liner  36  extending between intensifier mechanism  14  and stacked material  12 . Liner  36  inhibits intensifier mechanism  14  and membrane  20  contacting stacked material  12 . Liner  36  is coupled to side wall  26  and maintained in tension to facilitate forming stacked material  12 . In particular, liner  36  reduces indentations and irregularities in stacked material  12  when intensifier mechanism  14  induces a force in stacked material  12 . Moreover, liner  36  facilitates removal of formed stacked material  12  from system  10  and reduces deterioration and contamination of system  10 . In some embodiments, liner  36  is a release film. In further embodiments, liner  36  is a polypropylene material. In alternative embodiments, system  10  includes any liner  36  that enables system  10  to operate as described herein. For example, in some embodiments, intensifier mechanism  14  is semi-rigid and liner  36  is positioned above intensifier mechanism  14  and stacked material  12 . In further embodiments, liner  36  is coupled to any of stacked material  12 , intensifier mechanism  14 , and membrane  20  that enable system  10  to operate as described herein. 
       FIG. 3  is a schematic diagram of a sequence for forming stacked material  400  using a system  402  including an intensifier mechanism  404  positioned on stacked materials  400 .  FIG. 3  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description. System  402  includes intensifier mechanisms  404 , a housing  406 , a tool  408 , a membrane  410 , a liner  411 , and inserts  412 . Housing  406  defines an interior space  414  and includes a bottom wall  416 , a side wall  418  coupled to bottom wall  416 , and a perforated plate  420  disposed on bottom wall  416 . 
     Intensifier mechanism  404  is positioned on stacked material  400  adjacent tool  408  such that intensifier mechanism  404  induces a force in stacked material  400  as membrane  410  moves towards bottom wall  416 . In some embodiments, liner  411  is positioned between intensifier mechanism  404  and stacked material  400 . In the exemplary embodiment, intensifier mechanism  404  includes a plurality of bodies  422  and a support  424  coupling bodies  422  together. In particular, intensifier mechanism  404  includes two bodies  422  that each correspond to a shape of a portion of tool  408 . Support  424  is flexible and facilitates positioning intensifier mechanism  404  as membrane  410  moves towards bottom wall  416 . In particular, intensifier mechanism  404  is positioned adjacent tool  408  such that bodies  422  induce forces in stacked material  400  and the portions of tool  408  with shapes corresponding to intensifier mechanism  404 . In alternative embodiments, intensifier mechanism  404  has any configuration that enables system  402  to operate as described herein. For example, in some embodiments, intensifier mechanism  404  includes one body  422 . In further embodiments, intensifier mechanism  404  includes a plurality of bodies  422  that are not coupled together by support  424 . 
       FIG. 4  is a side view of a system  100  for forming stacked material  102 .  FIG. 4  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description.  FIG. 5  is a plan view of system  100 .  FIG. 5  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description. System  100  includes a housing  104 , a tool  106 , a membrane  108 , a temperature control unit  110 , a controller  112 , and a vacuum source  114 . Housing  104  includes a bottom wall  116 , a top wall  118 , and a side wall  120  extending between bottom wall  116  and top wall  118 . Bottom wall  116 , top wall  118 , and side wall  120  define an interior space  122 . In the exemplary embodiment, side wall  120  is coupled to bottom wall  116  and top wall  118  such that side wall  120  is substantially orthogonal to bottom wall  116  and top wall  118 . Moreover, bottom wall  116  is substantially rectangular and side wall  120  extends around the perimeter of bottom wall  116 . Accordingly, housing  104  is substantially box-shaped. In some embodiments, at least a portion of at least one of bottom wall  116 , top wall  118 , and side wall  120  is positionable between open and closed positions to facilitate access to interior space  122 . In further embodiments, housing  104  includes an access panel (not shown). In alternative embodiments, housing  104  has any configuration that enables system  100  to operate as described herein. For example, in some embodiments, top wall  118  is omitted. In further embodiments, at least one of bottom wall  116 , top wall  118 , and side wall  120  is angled to facilitate controlling the movement of membrane  108 . 
     In the exemplary embodiment, bottom wall  116  includes a perforated plate  124 . Perforated plate  124  facilitates airflow  125  between interior space  122  and the exterior of housing  104 . In particular, perforated plate  124  defines a plurality of openings  126  for airflow  125  through perforated plate  124 . Vacuum source  114  is coupled in flow communication with openings  126  to control the airflow  125  through perforated plate  124 . In addition, in some embodiments, any components of system  100 , such as tool  106 , include openings  126  to facilitate airflow  125  through housing  104 . Openings  126  are evenly spaced throughout perforated plate  124  such that airflow  125  through perforated plate  124  is substantially uniform. Other than openings  126 , housing  104  is substantially airtight such that the environment of interior space  122  is controlled during operation of system  100 . In alternative embodiments, housing  104  includes any openings  126  that enable system  100  to operate as described herein. In further embodiments, openings  126  are omitted. 
     Also, in the exemplary embodiment, tool  106  is disposed in interior space  122  and configured to support stacked material  102 . Stacked material  102  is coupled to tool  106  such that stacked material  102  is maintained at a desired tension. Tool  106  is coupled to bottom wall  116  and spaced from side wall  120  along the X-axis and the Y-axis. Tool  106  is configured to shape stacked material  102  into a component having a desired shape. For example, in some embodiments, tool  106  shapes stacked material into any of the following, without limitation: a geometrically-shaped structure, a component including undercuts, an airfoil, a turbine component, a shell, a stiffening element, a skin, a guide vane, an attachments clip, an L-frame, a Z-frame, an Omega-frame, a U-frame, and a shaped frame. In alternative embodiments, tool  106  has any configuration that enables system  100  to operate as described herein. 
     In addition, in the exemplary embodiment, membrane  108  extends over bottom wall  116 . In particular, membrane  108  is coupled to side wall  120  a distance  128  above bottom wall  116  in the Z-direction. Distance  128  is greater than a height  121  of tool  106 . In alternative embodiments, distance  128  is any measurement that enables system  100  to operate as described herein. In the exemplary embodiment, membrane  108  is configured such that at least a portion of membrane  108  moves towards bottom wall  116  during operation of system  100 . Membrane  108  is a flexible sheet structure and is at least partially elastic. At least initially, membrane  108  is spaced a minimum distance  129  from bottom wall  116 . As membrane  108  moves toward bottom wall  116 , membrane  108  stretches. Membrane  108  is coupled to side wall  120  such that membrane  108  is maintained in tension as membrane  108  moves toward bottom wall  116 . The tension facilitates membrane  108  moving in a controlled manner and contacting objects evenly. In alternative embodiments, membrane  108  has any configuration that enables system  100  to operate as described herein. For example, in some embodiments, membrane  108  includes a bladder and/or diaphragm structure. Membrane  108  is formed from any materials that enable system  100  to operate as described herein. For example, in some embodiments, membrane  108  is formed from any of the following stretchable materials, without limitation: silicone, rubber, release liners, vacuum liners, and combinations thereof. In the exemplary embodiment, membrane  108  is elastic such that membrane  108  is repeatedly stretched. In alternative embodiments, membrane  108  is configured for only a single use. 
     Moreover, in the exemplary embodiment, inserts  130  are disposed in interior space  122 . Inserts  130  are removably coupled to bottom wall  116  to facilitate repositioning inserts  130 . Inserts  130  are positioned between side wall  120  and tool  106 . In the exemplary embodiment, inserts  130  are inclined planes positioned adjacent side walls  120 . Inserts  130  extend substantially the entire span of side walls  120  along the Y-axis. In alternative embodiments, inserts  130  have any configuration that enables system  100  to operate as described herein. 
       FIG. 6  is a schematic diagram of a sequence for forming stacked material  102  using system  100  in a first configuration. In operation of system  100 , vacuum source  114  generates a negative pressure, i.e., a vacuum, in interior space  122  to facilitate membrane  108  moving towards bottom wall  116 . Controller  112  (shown in  FIG. 4 ) controls vacuum source  114  to regulate the pressure of interior space  122  and thereby control movement of membrane  108 . In addition, after stacked material  102  is formed, vacuum source  114  increases pressure in interior space  122  to cause membrane  108  to move away from bottom wall  116 . In alternative embodiments, membrane  108  is configured to move in any manner that enables system  100  to operate as described herein. For example, in some embodiments, the pressure above membrane  108  is increased to force membrane  108  into interior space  122 . In further embodiments, a biasing member is coupled to membrane  108  to facilitate controlled movement of membrane  108 . 
     As membrane  108  is drawn towards bottom wall  116 , membrane  108  contacts stacked material  102 , tool  106 , side wall  120 , bottom wall  116 , and inserts  130 . In alternative embodiments, membrane  108  contacts any components of system  100  that enable system  100  to operate as described herein. In the exemplary embodiment, stacked material  102  includes a liner  132  for membrane  108  to contact. Liner  132  inhibits membrane  108  contacting stacked material  102 . In some embodiments, liner  132  is removed after formation of stacked material  102 . In alternative embodiments, liner  132  is omitted. In further embodiments, liner  132  is included in any components of system  100 , including membrane  108 , that enables system  100  to operate as described herein. 
     In the exemplary embodiment, membrane  108  stretches as membrane  108  moves towards bottom wall  116 . In addition, membrane stretches as membrane  108  contacts stacked material  102 , tool  106 , side wall  120 , and/or bottom wall  116 . Inserts  130  at least partially support membrane  108  to reduce the amount membrane  108  stretches during operation of system  100 . In addition, inserts  130  facilitate membrane  108  moving in a controlled manner towards bottom wall  116 . As a result, inserts  130  facilitate system  100  forming stacked materials  102  with increased operating efficiency. 
     Also, in the exemplary embodiment, temperature control unit  110  maintains interior space  122  and stacked material  102  at a desired temperature during operation of system  100 . In some embodiments, temperature control unit  110  includes a heating and/or cooling source to increase and/or decrease the temperature of interior space  122  and, thereby, control the pliability of stacked material  102 . The heating and/or cooling source is disposed inside of housing  104 , disposed outside of housing  104 , and/or integrated into housing  104 . In alternative embodiments, tool  106  is maintained at a desired temperature by temperature control unit  110  and a heating and/or cooling source. In further embodiments, temperature control unit  110  includes a temperature controlled enclosure, such as an oven or a cooler, and housing  104  is positioned at least partially within the temperature controlled enclosure. In alternative embodiments, temperature control unit  110  has any configuration that enables system  100  to operate as described herein. 
     Moreover, in the exemplary embodiment, controller  112  controls vacuum source  114  to control movement of membrane  108 . In some embodiments, controller  112  controls any components of system  100  to facilitate the automation of the forming process. For example, in some embodiments, controller  112  controls a positioning member (not shown) to position stacked material  102  on tool  106 . In further embodiments, controller  112  controls the movement and positioning of inserts  130 . In addition, in some embodiments, controller  112  controls the positioning of intensifier mechanism  14 , intensifier mechanisms  204  (shown in  FIGS. 13-14  and described further below), and intensifier mechanisms  304  (shown in  FIG. 15  and described further below), and intensifier mechanisms  404  (shown in  FIG. 16  and described further below). In alternative embodiments, controller  112  has any configuration that enables system  100  to operate as described herein. 
       FIG. 7  is a schematic diagram of a sequence for forming stacked material  102  using system  100  in a second configuration.  FIG. 7  includes an X-axis and a Z-axis for reference during the following description. Perforated plate  124  is positioned at an angle  134  in relation to side wall  120 . Positioning perforated plate  124  at angle  134  facilitates stacked material  102  contacting membrane  108  and tool  106 . In addition, perforated plate  124  is at least partially raised a distance in the Z-direction. As a result, membrane  108  undergoes less stretching during operation of system  100  than if perforated plate  124  was located a greater distance from the starting position of membrane  108 . Inserts  130  are shaped to accommodate the position of perforated plate  124 . In particular, insert  130  adjacent the elevated portion of perforated plate  124  has a decreased height in the Z-direction in comparison to insert  130  adjacent the lower portion of perforated plate  124  such that the tops of insert  130  are approximately even with each other. As a result, inserts  130  contact membrane  108  at substantially the same point along the Z-axis during movement of membrane  108 . 
       FIGS. 8-10  are side views of system  100  including a plurality of inserts  131 . Inserts  131  have any shapes that enable system  100  to operate as described herein. For example, in some embodiments, inserts  131  have at least one of a cylindrical shape, a prism shape, and combinations thereof. In the exemplary embodiment, some inserts  131  are adjacent side wall  120  and some inserts  131  are adjacent tool  106 . In addition, inserts  131  are stacked on top of each other to form structures having different heights and shapes. Inserts  131  include flexible and/or rigid materials. Inserts  131  that are flexible deform at least slightly as membrane  108  contacts inserts  131 . Inserts  131  that are rigid maintain substantially the same shape as membrane  108  contacts inserts  131 . Accordingly, the rigidity and flexibility of inserts  131  is adjusted to control the movement of membrane  108  and provide support for membrane  108 . In alternative embodiments, inserts  131  have any configurations that enable system  100  to operate as described herein. 
     For example,  FIG. 8  is a side view of system  100  including inserts  131  having rectangular prism shapes. Some inserts  131  are stacked vertically and some inserts  131  are aligned horizontally.  FIG. 9  is a side view of system  100  including inserts  141  having a triangular prism shape.  FIG. 10  is a side view of system  100  including inserts  143  having a rectangular prism shape. 
     With reference to  FIGS. 9-10 , system  100  includes inserts  136  that extend through interior space  122  and function as dividers to divide interior space  122  into a plurality of forming zones  138 . A plurality of tools  106  are disposed in interior space  122  to facilitate forming a plurality of stacked materials  102 . In particular, one forming tool  106  and one stacked material  102  are disposed in each forming zone  138 . Insert  136  extends between tools  106  to define forming zones  138 . In some embodiments, insert  136  has a height  140  greater than a height  142  of tool  106  such that membrane  108  contacts insert  136  prior to contacting stacked material  102  supported on tool  106 . In some embodiments, insert  136  is formed by a single insert  130  having, for example, a substantially flat plate shape. In other embodiments, a plurality of inserts  130  are stacked to form insert  136 . In alternative embodiments, insert  136  has any configuration that enables system  100  to operate as described herein. For example, in some embodiments insert  136  is permanently affixed to or integral with housing  104 . 
       FIG. 11  is a schematic diagram of forming a plurality of stacked materials  102  using system  100 . In one embodiment, insert  136  is positioned between tools  106  to separate forming zones  138 . In another embodiment, insert  136  is omitted. In further embodiments, insert  136  hermetically separates forming zones  138  such that forming zones  138  form separate controlled environments. Accordingly, the movement of membrane  108  in each forming zone  138  is separately controlled. Moreover, in some embodiments, forming zones  138  each include separate membranes  108 . In alternative embodiments, forming zones  138  have any configuration that enables system  100  to operate as described herein. 
       FIG. 12  is a plan view of a plurality of systems  100  configured for forming a plurality of stacked materials  102 .  FIG. 12  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description. Systems  100  include different number of tools  106  in different numbers of forming zones  138 . Some forming zones  138  are separated by insert  136  and some forming zones  138  are not separated by insert  136 . Forming zones  138 , inserts  136 , and tools  106  are spaced along the X-axis and the Y-axis. Each forming zone  138  includes at least one tool  106 . In alternative embodiments, forming zones  138  have any configuration that enables system  100  to operate as described herein. In the exemplary embodiment, inserts  136  are substantially linear and positioned orthogonal or parallel to the X-axis and the Y-axis. In alternative embodiments, inserts  136  are non-linear. For example, in some embodiments, inserts  136  include any of the following without limitation: curves, S-shaped portions, C-shaped portions, and L-shaped portions. In further embodiments, inserts  136  are positioned at any angles in respect to the X-axis, a Y-axis, and a Z-axis that enable system  100  to operate as described herein. 
       FIG. 13  is a schematic diagram of a sequence of forming stacked material  200  using a system  202  including intensifier mechanisms  204 . FIG.  13  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description.  FIG. 14  is a schematic plan view of a sequence of forming stacked materials using system  202 .  FIG. 14  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description. System  202  includes intensifier mechanisms  204 , a housing  206 , a tool  208 , a membrane  210 , and inserts  212 . Housing  206  includes a bottom wall  214 , a side wall  216  coupled to bottom wall  214 , and a perforated plate  218  disposed on bottom wall  214 . Housing  206  defines an interior space  220 . During operation of system  202 , a negative pressure is generated in interior space  220  such that membrane  210  is drawn towards bottom wall  214 . As membrane  210  moves towards bottom wall  214 , membrane  210  contacts stacked material  200 , tool  208 , side wall  216 , inserts  212 , and intensifier mechanisms  204 . When membrane  210  contacts intensifier mechanisms  204 , intensifier mechanisms  204  move towards tool  208  and stacked material  200 . Intensifier mechanisms  204  are configured to press stacked material  200  against tool  208  such that stacked material  200  is compacted. Intensifier mechanisms  204  are configured to extend and move in directions along the X-axis, Z-axis, and Y-axis such that intensifier mechanisms contact stacked material  200  at predetermined locations. In particular, intensifier mechanisms  204  induce a force against a portion of stacked material  200  adjacent complex geometries on tool  208  to facilitate tool  208  shaping stacked material  200 . Moreover, intensifier mechanisms  204  limit the amount of stretching of membrane  210 . 
     Intensifier mechanisms  204  are disposed in interior space  220  and include a body  222  and a support  224 . Support  224  is coupled to housing  206  and body  222  such that body  222  is movable in relation to housing  206 . In particular, body  222  and support  224  are movably coupled together such that body moves along support  224 . Support  224  includes rails  226  coupled to opposed portions of side wall  216 . In alternative embodiments, support  224  is coupled to any components of system  202  that enable system  202  to operate as described herein. In the exemplary embodiment, rails  226  are angled along side wall  216  such that body  222  moves in directions along both the X-axis and the Z-axis. Body  222  extends between rails  226  and has a shape that corresponds to a desired shape of a component formed from stacked material  12  and engages a portion of tool  208 . In alternative embodiments, intensifier mechanisms  204  have any configuration that enables system  202  to operate as described herein. For example, in some embodiments, intensifier mechanisms  204  are positioned on the side of membrane  210  exterior to interior space  220  and compress membrane  210  and stacked material  200  against tool  208 . In further embodiments, intensifier mechanisms  204  are integrated into and/or coupled to tool  208  and/or membrane  210 . 
     In the exemplary embodiment, support  224  includes two rails  226  that are parallel. In some embodiments, support  224  includes any number of rails  226 , including one, that enable system  202  to operate as described herein. In further embodiments, support  224  includes a plurality of rails  226  and at least two rails of the plurality of rails  226  are not parallel. For example, in some embodiments, body  222  has an asymmetric shape such that body  222  extends between rails  226  that are not parallel. 
     Also, in the exemplary embodiment, intensifier mechanisms  204  are positionable between multiple positions. In particular, intensifier mechanisms  204  move from a position spaced from tool  106  and stacked material  200  to a position where intensifier mechanisms contact stacked material  200  to press stacked material  200  against tool  208  at a desired pressure. For example, in a first position, intensifier mechanisms  204  do not exert a substantial force against stacked material  200 . In a second position, intensifier mechanisms  204  cause compaction of stacked material  200 . In alternative embodiments, intensifier mechanisms  204  are positionable in any positions that enable system  202  to operate as described herein. In some embodiments, intensifier mechanisms  204  include biasing mechanisms, such as springs, to facilitate movement of intensifier mechanisms  204 . 
       FIG. 15  is a schematic diagram of a sequence of forming stacked material  300  using a system  302  including intensifier mechanisms  304 .  FIG. 15  includes an X-axis, a Y-axis, and a Z-axis for reference during the following description. System  302  includes intensifier mechanisms  304 , a housing  306 , a tool  308 , a membrane  310 , and inserts  312 . Housing  306  defines an interior space  314  and includes a bottom wall  316 , a side wall  318  coupled to bottom wall  316 , and a perforated plate  320  disposed on bottom wall  316 . 
     Intensifier mechanisms  304  include bodies  322  and a support  324 . Support  324  is movably coupled to bottom wall  316  at a joint  326  such that intensifier mechanism  304  rotates about joint  326 . In addition, support  324  is rotatably coupled to bodies  322  to facilitate bodies  322  rotating to contact stacked material  300  on tool  308 . Intensifier mechanism  304  is configured such that body  222  moves in directions along both the X-axis and the Z-axis. Bodies  322  are shaped to correspond to a shape of tool  308 . In some embodiments, intensifier mechanisms  304  and tool  308  are shaped to form corresponding male and female components. In alternative embodiments, intensifier mechanisms  304  have any configuration that enables system  100  to operate as described herein. 
     In reference to  FIGS. 4-6 and 13 , a method of forming stacked materials  102  includes coupling stacked material  102  to tool  106  disposed in interior space  122  of housing  104 . Vacuum source  114  generates a vacuum pressure in interior space  122  such that membrane  108  moves toward bottom wall  116 . Membrane  108  contacts stacked material  102  and forces stacked material  102  against tool  106  such that tool  106  shapes stacked material  102 . Temperature control unit  110  maintains stacked material  102  at a desired temperature. For example, in some embodiments, temperature control unit  110  increases the temperature of stacked material  102  to facilitate tool  106  shaping stacked material  102 . In further embodiments, the temperature of membrane  108  is increased. In some embodiments, membrane  108  contacts intensifier mechanism  304  to cause intensifier mechanism  304  to move. Intensifier mechanism  304  is positioned to cause stacked material  102  to contact tool  106  at predetermined locations. In further embodiments, intensifier mechanism  304  contacts stacked materials  102  with a predetermined force. In some embodiments, membrane  108  contacts insert  130  as membrane moves toward bottom wall  116 . Insert  130  supports membrane  108  and controls the movement of membrane  108 . 
     The above described systems include a membrane to facilitate forming stacked material into a component. The system includes a housing defining an interior space and a tool disposed in the interior space. The membrane is moved in the interior space towards the tool. In some embodiments, at least one insert is disposed in the interior space to control movement of the membrane and reduce stretching of the membrane. In further embodiments, at least one intensifier mechanism is disposed in the interior space to facilitate shaping the stacked material with the tool. The at least one intensifier mechanism is configured to cause the tool to shape the component into complex geometries. In some embodiments, the at least one intensifier mechanism provides contact pressure between the stacked material and the tool for increased compaction of the stacked material. 
     An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) increasing operating efficiency of systems for forming stacked materials; (b) enabling components formed from stacked materials to have complex geometries; (c) reducing the cost of forming stacked materials; (d) increasing the reliability of systems for forming stacked materials; (e) enabling stacked materials to be debulked during formation; (f) reducing cost and time required to form stacked materials; and (g) simplifying the forming process for stacked materials. 
     Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a field programmable gate array (FPGA), a reduced instruction set computer (RISC) processor, an application specific integrated circuit (ASIC), a programmable logic circuit (PLC), and/or any other circuit or processor capable of executing the functions described herein. In some embodiments, the methods described herein are encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device, and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term processor. 
     Exemplary embodiments of systems for forming stacked materials are described above in detail. The systems, and methods of operating and manufacturing such systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other forming systems, and are not limited to practice with only systems, and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications for forming materials. 
     Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing. 
     This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.