Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: To fabricate a composite item, a device places a composite ply on a curved form at about 0° relative to a longitudinal axis of the form. The form includes a web surface and a cap surface. The device includes a web compaction roller and a set of guides. The web compaction roller compacts a composite material upon the web surface and generate a web ply. The set of guide rollers urges against the cap surface. The compaction roller is directed along the form by the guide rollers.

Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, ?45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.

Abstract: An apparatus to prepare a preform for fabrication includes a mandrel, anchoring groove, anchoring device, tensioning groove, and tensioning device. The mandrel receives the preform. The mandrel has a first mandrel end and a second mandrel end. The preform has a first preform end and a second preform end. The anchoring groove is disposed at the first mandrel end. The anchoring device is configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The tensioning groove is disposed between the first mandrel end and the second mandrel end. The tensioning device is configured and located to urge a portion of the preform into the tensioning groove.

Abstract: By evacuating the resin feed tank to a pressure below atmospheric pressure, employing cyclic compaction, and controlling the net compaction pressure, we are better able to control a resin infusion process, particularly a vacuum assisted resin transfer molding process, and produce aerospace-grade fiber-reinforced resin composite having fiber volume fractions and tool-side surface finishes comparable to or exceeding those made using an autoclave.

Abstract: A composite hot drape vacuum forming method and apparatus. The apparatus includes an elongate vacuum chamber (12) having a lid (14) and a housing (16). An inflatable seal (26) is disposed between the lid (14) and the housing (16). Inflation of the inflatable seal (26) creates on airtight vacuum chamber. A heating blanket (36) is located in the bottom of the vacuum chamber (12). An inflatable bladder (28) is located on top of the heating blanket and extends approximately over the length of the vacuum chamber. The interior of the inflatable bladder is in fluid connection with the exterior of the vacuum chamber. Composite charges (40) are placed within the vacuum chamber on top of the vacuum bladder (28). Lay-up mandrels (42) are placed on top of the unformed composite charges and the vacuum chamber is closed and sealed. The composite charges (40) are heated using the heating blanket (36). The interior of the vacuum chamber is then evacuated.