Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

Abstract: Systems and methods for manufacturing unidirectional fiber prepreg tapes for CMC articles are provided. In one exemplary aspect, the method includes casting a matrix material on a carrier film to form a matrix film. The matrix material of the matrix film is then allowed to dry for a predetermined time. The matrix film is then wrapped on a drum and the matrix material is wet to a predetermined viscosity with a solvent. Thereafter, a fiber tow that includes of a plurality of fibers is wound about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape.

Abstract: A system for forming material includes a housing including at least one wall defining an interior space. The housing is configured to contain a pressurized fluid in the interior space. The system also includes at least one tool configured to shape the material. The at least one tool is movable along a path from a first position external to the housing to a second position at least partially within the interior space. The system further includes a membrane extending at least partially in the path of the at least one tool.

Abstract: In some embodiments, a shelter includes an impact-resistant panel having an energy-absorbing core positioned between two outer layers, wherein the energy-absorbing core includes a syntactic foam material that has a plurality of hollow microspheres compounded with a polymeric resin.

Abstract: Systems and methods for manufacturing unidirectional fiber prepreg tapes for CMC articles are provided. In one exemplary aspect, the method includes casting a matrix material on a carrier film to form a matrix film. The matrix material of the matrix film is then allowed to dry for a predetermined time. The matrix film is then wrapped on a drum and the matrix material is wet to a predetermined viscosity with a solvent. Thereafter, a fiber tow that includes of a plurality of fibers is wound about the drum so that the fiber tow penetrates into the matrix material and the matrix material impregnates the fiber tow to form the prepreg tape.

Abstract: A method of molding a composite structure having continuous fibers contained therein is disclosed. The method including the steps of compressing a first composite material in a mold; forming a cavity in the first composite material; placing a second composite material having continuous fibers contained therein in the cavity formed in the first composite material to minimize movement and distortion of the continuous fibers; compressing the first composite material such that the compression of the first composite material causes the first composite material to flow to edges of the second composite material; and allowing the first composite material to bond to the second composite material under molding temperature and pressure to form the composite structure.

Abstract: A method of molding a composite structure having continuous fibers contained therein is disclosed. The method including the steps of compressing a first composite material in a mold; forming a cavity in the first composite material; placing a second composite material having continuous fibers contained therein in the cavity formed in the first composite material to minimize movement and distortion of the continuous fibers; compressing the first composite material such that the compression of the first composite material causes the first composite material to flow to edges of the second composite material; and allowing the first composite material to bond to the second composite material under molding temperature and pressure to form the composite structure.

Abstract: A system for forming stacked material includes a housing defining an interior space. The housing includes a bottom wall and a side wall coupled to the bottom wall. At least one tool is configured to shape the stacked material. The at least one tool is disposed within the interior space. A membrane extends at least partially over the bottom wall and is spaced a distance from the bottom wall. The membrane is configured to move towards the bottom wall. At least one intensifier mechanism is disposed in the interior space and is configured to induce a force against a portion of the stacked material and against the at least one tool as the membrane is moved towards the bottom wall.

Abstract: A system for forming material includes a housing including at least one wall defining an interior space. The housing is configured to contain a pressurized fluid in the interior space. The system also includes at least one tool configured to shape the material. The at least one tool is movable along a path from a first position external to the housing to a second position at least partially within the interior space. The system further includes a membrane extending at least partially in the path of the at least one tool.