Patent ID: 7340933

Claim:
A method of forming an aircraft nacelle inlet noselip segment, the method comprising: (a) shaping a sheet of metal into a substantially U-shaped workpiece having a spanwise axis, opposed first and second ends, and opposed first and second edges; (b) placing the shaped workpiece on a substantially flexible first mandrel; (c) stretching the workpiece in a spanwise direction between the first and second ends while bending the workpiece and first mandrel together about a die, whereby the workpiece is plastically deformed to have a first shape; (d) removing the workpiece from the first mandrel; (e) placing the workpiece over a substantially rigid second mandrel that substantially corresponds in shape to the first shape of the workpiece; and (f) stretching the workpiece over the second mandrel between the first and second edges in a chordwise direction that is substantially transverse to the spanwise axis of the workpiece, whereby the workpiece is further plastically deformed to have a second shape.