Abstract: Methods for manufacturing a protective helmet for the military and other uses are disclosed. Embodiments of the method include winding ballistic-tolerant tape or fibers to create a preform, placing the preform into a first mold member having an interior that defines a helmet-shaped cavity, and pressing together the first mold member against a second mold member that includes a pressurized bladder member. The method may further include pressurizing the bladder until the first and second mold members are heated and adhesives have melted or cured. The first and second mold members are cooled and the preform is removed from the first and second mold members.

Abstract: Methods for manufacturing a protective helmet for the military and other uses are disclosed. Embodiments of the method include winding ballistic-tolerant tape or fibers to create a preform, placing the preform into a first mold member having an interior that defines a helmet-shaped cavity, and pressing together the first mold member against a second mold member that includes a pressurized bladder member. The method may further include pressurizing the bladder until the first and second mold members are heated and adhesives have melted or cured. The first and second mold members are cooled and the preform is removed from the first and second mold members.

Abstract: A method of winding fibers on a mandrel, the wound fibers being in tension, includes providing a source of fibers, imposing a torque on the source that resists dispensing the fibers from the source to exert a tension on the fibers, adding ultra-violet sensitive material that is polymerized by exposure to ultra-violet light to a resin matrix, impregnating dispensed fibers with the additive containing resin matrix, rotating a mandrel to wind the impregnated fibers on the mandrel, the rotation of the mandrel acting to overcome the torque on the source and putting the fibers in tension, and in situ, quasi instantaneously polymerizing the additive containing resin matrix on the mandrel by means of exposing the additive containing resin matrix to ultra-violet light for a selected period of time, such polymerization acting to lock in the tension in the fibers at the time of polymerization. A rail gun fabricated by means of the above method is further included.

Abstract: A method of winding fibers on a mandrel, the wound fibers being in tension, includes providing a source of fibers, imposing a torque on the source that resists dispensing the fibers from the source to exert a tension on the fibers, adding ultra-violet sensitive material that is polymerized by exposure to ultra-violet light to a resin matrix, impregnating dispensed fibers with the additive containing resin matrix, rotating a mandrel to wind the impregnated fibers on the mandrel, the rotation of the mandrel acting to overcome the torque on the source and putting the fibers in tension, and in situ, quasi instantaneously polymerizing the additive containing resin matrix on the mandrel by means of exposing the additive containing resin matrix to ultra-violet light for a selected period of time, such polymerization acting to lock in the tension in the fibers at the time of polymerization. A rail gun fabricated by means of the above method is further included.

Abstract: A light weight high performance vessel, e.g., tank and method of making same which is produced primarily from reinforced plastic composite materials. The vessel can be used for the containment of liquids or pressurized gases. The tank is comprised of an inner shell which is split to remove a mandrel on which it is formed and to install components in the inner shell. The inner shell pieces are then secured together by means of a joinder ring. An outer shell is then formed around and completely encapsulates the inner shell. There is also no need for the employment of an inner liner although one can be used.

Abstract: A vision inspection system is provided in which eight optical images are instantaneously recorded on singular image frames which are output from two optical cameras. An illumination source is provided for illuminating four spaced apart inspection regions which are disposed about an inspection window. Two optical signals of reflected light emanate from each of the four inspection regions and are directed toward two optical cameras, with the two optical signals from each of the optical regions being at different viewing angles and preferably from a single focal point. Optical directing members receive the optical signals from the various regions and direct the light to respective ones of the cameras. The optical directing members are selectively adjustable for accommodating components of various sizes. The optical inspection of each component instantaneously occurs by recording the eight optical images, on two frames, one frame being recorded by each of the cameras.

Abstract: A filament wound wheel is shown having a high percentage of continuous fiber oriented in the optimum load bearing direction for maximum strength. Also shown is a manufacturing method for the wheel including the steps of polar winding a continuous filament on a split mandrel to form a filament winding, slitting the filament winding on the mandrel to form two preforms, placing the two preforms in a back-to-back configuration, pressing each preform upon its split mandrel under heat to cure and join the preforms and separating the split mandrels from the joined preforms.

Abstract: An energy absorbing beam is shown which may be manufactured by wrapping several side-by-side strands of resin coated filaments about an increasing number of pins mounted upon a base. The base then becomes part of a mold to which heat and pressure is applied for forming the coated filaments into a beam having a variable cross section with variable thickness. Devices for fastening the beam may be molded into the beam by passing the coated filaments about the fasteners as the filaments are wrapped about the pins.