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A method for forming a bend in composite panel. In one advantageous embodiment, a method is used to form a bend in a composite panel. An angle and a radius bend are identified for the bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the compo

A method for forming a bend in composite panel. In one advantageous embodiment, a method is used to form a bend in a composite panel. An angle and a radius bend are identified for the bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2π*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA−2K(R−T), wherein K is Tan(A/2) and T is a thickness of the composite panel. The composite panel with the slot is bent to form the bend.

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1. A method for forming a bend in a composite panel having a first layer, a core, and a second layer, the method comprising: removing a portion of the first layer and the core with a cutter tool so as to form a first curved surface in the core and a second curved surface in the core, the first curve

1. A method for forming a bend in a composite panel having a first layer, a core, and a second layer, the method comprising: removing a portion of the first layer and the core with a cutter tool so as to form a first curved surface in the core and a second curved surface in the core, the first curved surface characterized by a first radius, and the second curved surface characterized by a second radius, so as to define a bend slot width in the first layer and the core and so as to define a bend slot allowance width in the core, the bend slot allowance width proximate the second layer, and the bend slot width being narrower than the bend slot allowance width; andbending the composite panel to form a bend radius in the composite panel such that the bend radius substantially matches the first radius and the second radius. 2. The method of claim 1 further comprising the step of disposing a support proximate the bend radius of the panel. 3. The method of claim 2 wherein the support comprises one selected from the group consisting of a doubler and a bracket. 4. The method of claim 2 wherein the bending of the composite panel forms an intersection of a first edge and a second edge of the composite panel and wherein the support is attached to the composite panel proximate the intersection. 5. The method of claim 2 wherein the support provides support and maintains the bend radius in the composite panel. 6. The method of claim 1 wherein the composite panel is characterized by a thickness and wherein the bend radius is greater than the thickness of the composite panel. 7. The method of claim 1 further comprising the steps of: identifying an angle and a radius bend for the bend; andidentifying a location of the bend in the composite panel. 8. The method of claim 7 wherein the step of removing a portion of the core comprises cutting a slot having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width in which the bend allowance width is: BA=2π*A/360wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle and in which the bend slot width is: BS=BA−2K(R−T) wherein K is Tan(A/2) and T is a thickness of the composite panel. 9. The method of claim 8 wherein the slot is configured such that after the bending step open space in the slot is substantially minimized. 10. The method of claim 8 wherein the slot further defines a first curved surface and a second curved surface in the composite panel and wherein the first curved surface and the second curved surface define a curvature substantially similar to the radius bend. 11. The method of claim 1, wherein the first layer comprising a resin pre-impregnated fabric. 12. A method for forming a bend in a composite panel wherein the composite panel comprises a first layer, a core, and a second layer, the method comprising: identifying a location for the bend in the composite panel to form an identified location, the first layer of the composite panel comprising a resin pre-impregnated fabric;removing a portion of the first layer and the core with a cutter tool so as to form a slot having a curved flange in the core of the composite panel at the identified location, the curved flange comprising a first curved surface in the core and a second curved surface in the core, and so as to define a bend slot width in the first layer and the core and so as to define a bend slot allowance width in the core, the bend slot allowance width proximate the second layer, and the bend slot width being narrower than the bend slot allowance width; andbending the composite panel with the slot to form the bend so as to form a bend radius, wherein the bend radius is substantially the same as the first curved surface and the second curved surface. 13. The method of claim 12, wherein the curved flange has a bend allowance width larger than a bend slot width at the location. 14. The method of claim 13, wherein the bend allowance width is: BA=2π*A/360 wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. 15. The method of claim 14, wherein the bend slot width is: BS=BA−2K(R−T) wherein K is Tan(A/2) and T is a thickness of the composite panel. 16. The method of claim 12, wherein the forming step comprises: cutting the slot with a tool. 17. The method of claim 16, wherein the tool is a cutter having a shape corresponding to the bend allowance width, the bend slot width, the first curved surface, and the second curved surface. 18. The method of claim 17, wherein the cutter is attached to a computer numerical control router. 19. The method of claim 12, wherein the composite panel comprises a filler layer between a first composite layer and a second composite layer. 20. The method of claim 19, wherein the slot is formed in the first composite layer and the filler layer. 21. The method of claim 20, wherein the filler layer is a honeycombed panel. 22. The method of claim 12, wherein the composite panel with the bend is a part for an aircraft. 23. A method for forming a bend in a composite panel with a core, the method comprising: removing a portion of the core with a cutter tool; andbending the composite panel to form a bend radius in the composite panel, the bend allowance width being substantially: BA=2π*A/360 wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle.