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: In a method of producing symmetrical carbon fiber reinforced composite parts, a plurality of sheets of fibrous material configured as a single structure are positioned on a tool surface where the single structure is comprised of a first composite part joined to a symmetric, second composite part. The single structure is infused with resin and cured on the tool surface, producing a single cured structure comprised of a first cured composite part joined to a second cured composite part. The single cured structure is then divided along a dividing plane, producing the symmetric first cured composite part and second cured composite part.

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 of composite part manufacturing includes inserting a tooling pin of a magnet into a ply charge. The method also includes coupling the ply charge to a tool using the magnet and a second magnet of the tool. The magnet positions the ply charge on the tool. The tooling pin provides a retaining force to resist movement of the ply charge. The method further includes applying resin to the ply charge and curing the resin to form a cured composite material.

Abstract: A method and system for fabricating a composite structure is provided. At least a first layer of reinforcement material is placed on a surface of a tool. At least a first layer of veil material is then wrapped around the first layer of reinforcement material while the first layer of reinforcement material is positioned on the tool to produce a first reinforced ply.

Abstract: A method for fabricating a hat stiffener which includes a step of positioning two or more reinforcement fiber layers about a mandrel. The method further includes a step of cutting through the two or more reinforcement fiber layers forming a first stack of first end portions of the two or more reinforcement fiber layers and a second stack of second end portions of the two or more reinforcement fiber layers wherein the first and second stacks are in overlying relationship with respect to the mandrel. In addition, the method further includes moving the first stack of the first end portions and the second stack of the second end portions of the two or more reinforcement fiber layers out of overlying relationship with respect to the mandrel.

Abstract: In a method of producing symmetrical carbon fiber reinforced composite parts, a plurality of sheets of fibrous material configured as a single structure are positioned on a tool surface where the single structure is comprised of a first composite part joined to a symmetric, second composite part. The single structure is infused with resin and cured on the tool surface, producing a single cured structure comprised of a first cured composite part joined to a second cured composite part. The single cured structure is then divided along a dividing plane, producing the symmetric first cured composite part and second cured composite part.

Abstract: A method of composite part manufacturing includes inserting a tooling pin of a magnet into a ply charge. The method also includes coupling the ply charge to a tool using the magnet and a second magnet of the tool. The magnet positions the ply charge on the tool. The tooling pin provides a retaining force to resist movement of the ply charge. The method further includes applying resin to the ply charge and curing the resin to form a cured composite material.

Abstract: A method for fabricating a hat stiffener which includes a step of positioning two or more reinforcement fiber layers about a mandrel. The method further includes a step of cutting through the two or more reinforcement fiber layers forming a first stack of first end portions of the two or more reinforcement fiber layers and a second stack of second end portions of the two or more reinforcement fiber layers wherein the first and second stacks are in overlying relationship with respect to the mandrel. In addition, the method further includes moving the first stack of the first end portions and the second stack of the second end portions of the two or more reinforcement fiber layers out of overlying relationship with respect to the mandrel.

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 and system for fabricating a composite structure is provided. At least a first layer of reinforcement material is placed on a surface of a tool. At least a first layer of veil material is then wrapped around the first layer of reinforcement material while the first layer of reinforcement material is positioned on the tool to produce a first reinforced ply.

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.