Abstract: A drop draw and extrusion method that creates anchor points around, within, or around and within, the region where a two dimensional fibrous architecture is deposited. Between the anchor points, a nozzle translates at high speeds to draw, extrude, or draw and extrude (depending on the print settings), a filament from the nozzle and build a two dimensional network of filaments connected by the anchors. Webbed architectures fabricated using the methods described herein exhibit superior structural properties.

Abstract: A composite article including fiber tows and a network including material drawn or pulled between the fiber tows. The network forms a physical barrier reducing propagation of cracks in the composite article. Exemplary structures described herein are the first to use a novel cellular architecture to toughen resin infused composites and create a continuous through thickness reinforcement that does not induce fiber breakage.

Abstract: A three dimensional permeable thermoplastic tape useful for joining of layers of fiber tows (plies) together so as to form highly toughened resin infused structures. In one or more embodiments, the tape is manufactured using three dimensional printing and is applied between layers of fiber tows so as to tack the layers of fiber tows in place and prevent movement of the layers of fiber tows.

Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method of fabricating a composite part. The method includes providing a preform on a tool mandrel, positioning sensors around the preform according to a target shape of the composite part, and sealing the preform with a vacuum bag to form a chamber. The method also includes applying temperature and pressure to the chamber to infuse a resin into the preform to create a composite preform undergoing infusion, monitoring a thickness of the composite preform prior to completing cure, and adjusting at least one of the temperature and the pressure prior to completing cure based on the thickness.

Abstract: A drop draw and extrusion method that creates anchor points around, within, or around and within, the region where a two dimensional fibrous architecture is deposited. Between the anchor points, a nozzle translates at high speeds to draw, extrude, or draw and extrude (depending on the print settings), a filament from the nozzle and build a two dimensional network of filaments connected by the anchors. Webbed architectures fabricated using the methods described herein exhibit superior structural properties.

Abstract: A composite article including fiber tows and a network including material drawn or pulled between the fiber tows. The network forms a physical barrier reducing propagation of cracks in the composite article. Exemplary structures described herein are the first to use a novel cellular architecture to toughen resin infused composites and create a continuous through thickness reinforcement that does not induce fiber breakage.

Abstract: A filament network for a composite structure may include a number of fiber layers, wherein each fiber layer includes a fiber bundle and a filament layer at least partially covering the fiber bundle, the filament layer including discontinuous filaments including at least one of different length filaments including first length filaments and second length filaments, wherein the first length filaments include a first length and the second length filaments include a second length, and wherein the first length is different than the second length and different type filaments including first type filaments and second type filaments, wherein the first type filaments include a first material composition, wherein the second type filaments include a second material composition, and wherein the first material composition is different that the second material composition, and a resin binding the number of fiber layers together.

Abstract: A filament network for a composite structure may include a number of fiber layers, wherein each fiber layer includes a fiber bundle and a filament layer at least partially covering the fiber bundle, the filament layer including discontinuous filaments including at least one of different length filaments including first length filaments and second length filaments, wherein the first length filaments include a first length and the second length filaments include a second length, and wherein the first length is different than the second length and different type filaments including first type filaments and second type filaments, wherein the first type filaments include a first material composition, wherein the second type filaments include a second material composition, and wherein the first material composition is different that the second material composition, and a resin binding the number of fiber layers together.

Abstract: A drop draw and extrusion method that creates anchor points around, within, or around and within, the region where a two dimensional fibrous architecture is deposited. Between the anchor points, a nozzle translates at high speeds to draw, extrude, or draw and extrude (depending on the print settings), a filament from the nozzle and build a two dimensional network of filaments connected by the anchors. Webbed architectures fabricated using the methods described herein exhibit superior structural properties.

Abstract: A composite article including fiber tows and a network including material drawn or pulled between the fiber tows. The network forms a physical barrier reducing propagation of cracks in the composite article. Exemplary structures described herein are the first to use a novel cellular architecture to toughen resin infused composites and create a continuous through thickness reinforcement that does not induce fiber breakage.

Abstract: A composite article including a plurality of layers each comprising bundles of fibers separated by spaces; pins bonded to a side of at least one of bundles and extending or built through the spaces between the layers; and a resin combined with the layers and the pin. The pins form a physical barrier preventing or reducing propagation of cracks in an x-y plane of the composite article.

Abstract: A drop draw and extrusion method that creates anchor points around, within, or around and within, the region where a two dimensional fibrous architecture is deposited. Between the anchor points, a nozzle translates at high speeds to draw, extrude, or draw and extrude (depending on the print settings), a filament from the nozzle and build a two dimensional network of filaments connected by the anchors. Webbed architectures fabricated using the methods described herein exhibit superior structural properties.

Abstract: A three dimensional permeable thermoplastic tape useful for joining of layers of fiber tows (plies) together so as to form highly toughened resin infused structures. In one or more embodiments, the tape is manufactured using three dimensional printing and is applied between layers of fiber tows so as to tack the layers of fiber tows in place and prevent movement of the layers of fiber tows.

Abstract: A composite article including fiber tows and a network including material drawn or pulled between the fiber tows. The network forms a physical barrier reducing propagation of cracks in the composite article. Exemplary structures described herein are the first to use a novel cellular architecture to toughen resin infused composites and create a continuous through thickness reinforcement that does not induce fiber breakage.

Abstract: A tool and its method of use, where at least one channel is formed in a tool surface of a tool and one or more grooves are formed in at least one surface of a mandrel that is dimensioned to be positioned in the channel. The grooves formed in the mandrel and the channel in the tool surface distribute and deliver resins supplied to the tool surface through layers of fiber reinforced material positioned on the tool surface and in the channel, and position over the mandrel. The grooves formed in the mandrel and the channel formed in the tool surface direct a flow of liquid resin and infuse the layers of fiber reinforced material with the liquid resin.

Abstract: A composite structure is fabricated by laying up at least one ply of fiber reinforcement and at least one layer of resin on a tool. The resin film layer is formed by laying strips of resin film. The fiber reinforcement is infused with resin from the resin layer.

Abstract: A composite fiber may include at least one reinforcing filament formed of a first material. A second material maybe systematically deposited in a printed onto the at least one reinforcing filament such that at least one of a length, a width, and a thickness of the second material varies across a surface of the at least one reinforcing filament. The printed pattern may alter one or more properties of a composite structure containing the composite fiber.

Abstract: A composite structure is fabricated by laying up at least one ply of fiber reinforcement and at least one layer of resin on a tool. The resin film layer is formed by laying strips of resin film. The fiber reinforcement is infused with resin from the resin layer.

Abstract: A directional cold spray nozzle defines a flow passageway that includes a bend for redirecting flow from a first flow direction to a second flow direction different from the first flow direction, wherein the flow passageway is divergent through at least a portion of the bend. The flow passageway may be convergent prior to becoming divergent in the path of flow. The directional cold spray nozzle simultaneously accelerates the powder and carrier gas and changes the spray direction of the spray plume to reach interior bore surfaces and other surfaces that are difficult or impossible to reach with a straight nozzle.