Abstract: A method of fabricating an article by fused filament fabrication.

Abstract: The invention relates to methods of bonding and a conductively bonded joint, provided by high loadings of conductively coated nano scale particulate fillers in a conductive adhesive in combination with a conductive intermediary structure, more particularly to a lightning strike resilient bonded joint between fibre reinforced polymer composites. A method of joining a first fibre reinforced polymer composite surface and a second fibre reinforced polymer composite surface, comprising the steps of providing a conductive intermediary structure between said first and second surfaces, filling the void between said surfaces and enveloping said intermediary structure with a conductive adhesive, curing the conductive adhesive to form a bonded first and second surface. A conductive adhesive comprising a curable binder and a high aspect ratio nanoscale carbon particulate filler present in the range of from 0.1 to 40% wt, wherein said particulate filler comprises a metal coating.

Abstract: A structure to be monitored for damage and a method of monitoring the structure for damage are provided. The structure has a coating thereon, the coating defining a surface having characteristics which vary in a predetermined manner with damage to the structure. The surface has a series of conductive tracks applied thereto and in intimate contact therewith such that the said predetermined variation of the surface characteristics will vary the resistance of the series of conductive tracks in a predetermined manner in order to determine both location and extent of damage.

Abstract: The invention relates to methods and a novel powdered curable monomer which may be used to manufacture bulk polymers, adhesives and coatings composite materials with high percentage weight inclusions of particulate filler materials, more specifically to fibre reinforced polymer composite materials with high percentage weight inclusions of particulate filler materials. The preferred particulate filler materials are carbon nanotubes. The method according to the invention allows greater than 0.5 wt % of carbon nanotubes, typically greater 10% wt of carbon nanotubes or other high aspect ratio fillers to be readily incorporated in the resin matrix, before being applied to the fibre reinforcing plys.

Abstract: A method for forming a joint between a fiber reinforced composite component and a metallic component and a joint are provided. The metallic component and the composite component each define a joint surface for mating with the joint surface of the other to join the two components together and the composite component defines a free surface opposed to the joint surface thereof. The joint surface of the metallic component defines an array of pins extending therefrom with each pin defining a pin head at an end distal from the joint surface. The method includes the steps of pressing together the joint surfaces of the two components whereby to cause the array of pins to penetrate through the fiber reinforcing material, and modifying the effective cross sectional shape of the pin heads whereby to increase the constraint applied to the composite component against peeling of the composite component from the joint surface of the metallic component.

Abstract: A structure to be monitored for damage and a method of monitoring the structure for damage are provided. The structure has a coating thereon, the coating defining a surface having characteristics which vary in a predetermined manner with damage to the structure. The surface has a series of conductive tracks applied thereto and in intimate contact therewith such that the said predetermined variation of the surface characteristics will vary the resistance of the series of conductive tracks in a predetermined manner in order to determine both location and extent of damage.

Abstract: Apparatus and a method of forming a composite component (8) by additive layer manufacturing are provided. The method includes the steps of providing an elongate tape (2) of carbon nanotubes (CNTs), applying stretching force to the tape (2) whereby to align the carbon nanotubes to the tape and form an aligned tape (27), impregnating the tape (27) with matrix material (40, 48, 50), forming the aligned tape (27) into portions (43) of required size and transferring the portions as required to a component build location whereby to form the component (8), layer by layer.

Abstract: A flexible manufacturing tool is provided. The tool includes a multi-layer generally planar sheet of material defining a tool surface thereon, means such as spaced jacks to controllably deform the sheet by applying out-of-plane deforming forces to the sheet and means selectively to increase and decrease interlayer shear or frictional forces whereby to vary the flexural stiffness of the sheet. Such means may comprise applying a vacuum between the layers to increase interlayer friction or the use of softenable polymers between the layers.

Abstract: The invention relates to methods of bonding and a conductively bonded joint, provided by high loadings of conductively coated nano scale particulate fillers in a conductive adhesive in combination with a conductive intermediary structure, more particularly to a lightning strike resilient bonded joint between fibre reinforced polymer composites. A method of joining a first fibre reinforced polymer composite surface and a second fibre reinforced polymer composite surface, comprising the steps of providing a conductive intermediary structure between said first and second surfaces, filling the void between said surfaces and enveloping said intermediary structure with a conductive adhesive, curing the conductive adhesive to form a bonded first and second surface. A conductive adhesive comprising a curable binder and a high aspect ratio nanoscale carbon particulate filler present in the range of from 0.1 to 40% wt, wherein said particulate filler comprises a metal coating.

Abstract: The invention relates to the manufacture of hybrid joints more particularly to the manufacture of joints between parts made of differing materials and most particularly to the manufacture of a metallic component comprising a plurality of preformed projections which penetrate composite fabric within a composite part. Particularly there is a method of forming an array of projections on a surface of a metallic component, the method including the steps of bringing at least one preformed projection into at least close proximity to the surface of the component and causing a portion of the projection and a portion of the component in the region of an intersection thereof to at least partially melt, and causing them to be joined together.

Abstract: A method for forming a joint between a fibre reinforced composite component and a metallic component and a joint are provided. The metallic component and the composite component each define a joint surface for mating with the joint surface of the other to join the two components together and the composite component defines a free surface opposed to the joint surface thereof. The joint surface of the metallic component defines an array of pins extending therefrom with each pin defining a pin head at an end distal from the joint surface. The method includes the steps of pressing together the joint surfaces of the two components whereby to cause the array of pins to penetrate through the fibre reinforcing material, and modifying the effective cross sectional shape of the pin heads whereby to increase the constraint applied to the composite component against peeling of the composite component from the joint surface of the metallic component.

Abstract: There is disclosed armor having an outer metallic layer, an inner fiber composite layer, and a supporting framework between the inner and outer layers. The supporting framework can include projections from the outer layer arranged to mechanically interlock with the fibers of the fiber composite, and can be arranged to provide an open region between the inner and outer layers that can be filled with a functional filler material.

Abstract: The invention relates to methods and a novel powdered curable monomer which may be used to manufacture bulk polymers, adhesives and coatings composite materials with high percentage weight inclusions of particulate filler materials, more specifically to fibre reinforced polymer composite materials with high percentage weight inclusions of particulate filler materials. The preferred particulate filler materials are carbon nanotubes. The method according to the invention allows greater than 0.5 wt % of carbon nanotubes, typically greater 10% wt of carbon nanotubes or other high aspect ratio fillers to be readily incorporated in the resin matrix, before being applied to the fibre reinforcing plys.

Abstract: A flow sensor and fastener assembly, is disclosed which includes at least the following modules: a sensor housing and a fastener element; wherein: the sensor housing is adapted to receive a flow-based sensor, e.g. a MEMS airflow sensor; the sensor housing includes a connection for transmitting sensing signals from a fitted flow-based sensor; the fastener element includes a head and a shank, at least part of the shank being externally threaded; the fastener element includes a bore extending through the whole length of the fastener element; and the bore is shaped at the head end of the fastener element to provide a sensor housing receiving part.

Abstract: There is disclosed armour having an outer metallic layer, an inner fibre composite layer, and a supporting framework between the inner and outer layers. The supporting framework can include projections from the outer layer arranged to mechanically interlock with the fibres of the fibre composite, and can be arranged to provide an open region between the inner and outer layers that can be filled with a functional filler material.

Abstract: A flow sensor and fastener assembly, is disclosed which includes at least the following modules: a sensor housing and a fastener element; wherein: the sensor housing is adapted to receive a flow-based sensor, e.g. a MEMS airflow sensor; the sensor housing includes a connection for transmitting sensing signals from a fitted flow-based sensor; the fastener element includes a head and a shank, at least part of the shank being externally threaded; the fastener element includes a bore extending through the whole length of the fastener element; and the bore is shaped at the head end of the fastener element to provide a sensor housing receiving part.