Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: An airfoil-shaped body (such as a wing or a flight control surface) comprising a base assembly made of composite material, which base assembly in turn comprises a base skin and one or more hat-shaped spars integrally formed with the base skin. The airfoil-shaped body further comprise a close-out skin that is attached to the hat-shaped spars using fasteners. The method for manufacturing such an airfoil-shaped body uses a resin infusion process.

Abstract: A method for assembling a stiffened composite structure includes a step of positioning a plurality of dry fibers along a first side of a pre-preg composite laminate skin element wherein the pre-preg composite laminate skin element is dimensionally changeable. The method further includes a step of positioning an interlayer between the plurality of dry fibers and the first side of the pre-preg composite laminate skin element and a step of infusing the plurality of dry fibers with a resin forming a plurality of infused fibers. The method also includes a step of co-curing the pre-preg composite laminate skin element and the plurality of infused fibers.

Abstract: A method for assembling a stiffened composite structure includes a step of co-bonding a cured infused composite stiffener to a pre-preg composite laminate skin element, wherein the pre-preg composite laminate skin element is dimensionally changeable. Another method for assembling a stiffened composite structure includes a step of coupling a cured infused composite stiffener which includes a preform of a plurality of braided fibers to a pre-preg composite laminate skin element, wherein the pre-preg composite laminate skin element is dimensionally changeable.

Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.

Abstract: A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.

Abstract: A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.

Abstract: A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.