Abstract: A spliced fiber tow (40) having a uniform density along its entire length is provided. The spliced fiber tow is manufactured by rarefying the ends (22, 32) of the two fiber tow segments to be joined, aligning the rarefied regions (26, 36) and then applying pressurized gas to entangle the filaments in the rarefied regions. An apparatus (50) for forming the spliced fiber tow includes a pair of rarefying blades (86, 92) and an entanglement element (58).

Abstract: An apparatus to apply a resin impregnated tape to the surface of a molding tool, the apparatus including: an upper frame mounted to a base frame, the upper frame having mounted thereon a spool holding assembly for holding a spool of resin impregnated tape wound thereon, a tape compaction assembly including a compaction roller configured to conform to the surface of the molding tool for compacting the resin impregnated tape onto the surface of the molding tool, and a tape tensioning system for exerting tension on the resin impregnated tape. The base frame includes a tracking system for tracking the surface of the molding tool, the base frame being reciprocally movable with respect to the surface of the molding tool.

Abstract: A spliced fiber tow (40) having a uniform density along its entire length is provided. The spliced fiber tow is manufactured by rarefying the ends (22, 32) of the two fiber tow segments to be joined, aligning the rarefied regions (26, 36) and then applying pressurized gas to entangle the filaments in the rarefied regions. An apparatus (50) for forming the spliced fiber tow includes a pair of rarefying blades (86, 92) and an entanglement element (58).

Abstract: A nonwoven veil comprising an oxidized PAN fiber having an aromaticity index between 40 and 60 percent, wherein the veil is thermally stable in temperature ranges used for typical composite fabrication processes. Thermally stable nonwoven veil and composites containing the veil are disclosed. The nonwoven veil could be used as a surface finish having improved properties as measured by surface waviness and lack of defects.

Abstract: An apparatus and method for winding a towpreg having a spool winding machine having a rod-shaped body for mounting a core of a spool, wherein the core is shuttled on the rod-shaped body to allow the towpreg to maintain a straight path substantially normal to an axis of the rod-shaped body are disclosed.

Abstract: A large-tow fiber placement system having (1) a creel, (2) a tow feeding mechanism, (3) a tow cutting mechanism, and (4) a tow consolidation system, wherein the creel shuttles a spool to maintain a substantially fixed exit path of a large-tow exiting the spool, the tow feeding mechanism has a head that is cooled by a fluid to control integrity of the large-tow and the tow consolidation system has interlocking shoes to provide a continuous application of the head is disclosed.

Abstract: An apparatus for splitting a fiber tow, the apparatus having a spreading bar comprising a crown and a circular or oval-shaped splitter bar comprising grooves around the circumference of the splitter bar, wherein each of the grooves does not circumscribe the complete circumference of the splitter bar, and a method therefor are disclosed.