Abstract: Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outboard section includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section. The system also includes center planked stringers within the center section and are co-cured with composite skin at the center section.

Abstract: A method and an apparatus are presented. The method locally compensates for cure related deformations in a composite skin by laying up a composite material on a compensation surface of a slip sheet designed to form a modified outer mold line different from a designed shape, wherein the slip sheet is held against a forming surface of a layup tool, wherein the forming surface is designed to form an outer mold line of the designed shape.

Abstract: A hybrid carbon/fiberglass structural component or beam for an aircraft is constructed with layers of strips of glass fibers interspersed with layers of strips of unidirectional carbon fibers where the carbon fibers are oriented only in alignment with or along the longitudinal direction of the length of the beam thereby adding strength and stiffness to the beam while reducing weight and manufacturing costs.

Abstract: A hybrid carbon/fiberglass structural component or beam for an aircraft is constructed with layers of strips of glass fibers interspersed with layers of strips of unidirectional carbon fibers where the carbon fibers are oriented only in alignment with or along the longitudinal direction of the length of the beam thereby adding strength and stiffness to the beam while reducing weight and manufacturing costs.

Abstract: An aircraft comprises a forward-facing aircraft section including composite aircraft skin and a substructure for the skin. The substructure includes a plurality of hoop-shaped composite frames. The frames are designed to deflect elastically under bird impact loads.

Abstract: An apparatus, a vehicle and a method for securing intermodal cargo containers is provided. Couplers include pins and bottom supports to engage apertures and bottom surfaces of corner fittings for intermodal cargo containers. The couplers may also include sidewall supports to engage forward facing side surfaces of the corner fittings. The pins, bottom supports, and sidewall supports hold an intermodal cargo container in place through a relatively large range of acceleration forces without damaging the corner fittings of the intermodal cargo containers. The couplers are selectively movable from a retracted position to an extended position to engage the corner fittings of the intermodal cargo containers.

Abstract: A composite laminate has a primary axis of loading and comprises a plurality resin plies each reinforced with unidirectional fibers. The laminate includes cross-plies with fiber orientations optimized to resist bending and torsional loads along the primary axis of loading.

Abstract: Systems and methods are provided for structurally supporting an aircraft wing. The system comprises a section of aircraft wing that includes skin. The skin surrounds an internal volume of the wing and comprises layers of Carbon Fiber Reinforced Polymer (CFRP) having fiber orientations aligned to bear shear stresses applied to the wing. The section of aircraft wing also includes planked stringers that are laterally oriented within the wing, contact the skin within the internal volume, are attached to the skin, and comprise layers of CFRP having fiber orientations that are aligned to bear bending at the wing. Furthermore, the section includes spars that are positioned between planked stringers on an upper portion of the wing and planked stringers on a lower portion of the wing, wherein the spars are aligned with the planked stringers.

Abstract: Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outboard section includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section. The system also includes center planked stringers within the center section and are co-cured with composite skin at the center section.

Abstract: Disclosed are structures and features of a space frame aircraft. In particular, this disclosure relates to bracing for a space frame aircraft.

Abstract: A method and apparatus for forming a sandwich structure is presented. A sandwich structure comprises a metallic core layer and a thermoplastic layer on a first side of the metallic core layer. The thermoplastic layer is consolidated against the first side of the metallic core layer.

Abstract: A wheel having a longitudinal plane normal to an axis of rotation. The wheel has a rim with side surfaces on opposite sides of the longitudinal plane. A hub is concentrically disposed relative to the rim. Two unitary side elements are disposed on opposite sides of the longitudinal plane and are coupled to the rim and to end portions of the hub. Each of the unitary side elements has an annular sidewall, a flange portion, and a plurality of spokes that do not cross the longitudinal plane and that integrally interconnect the annular sidewall and the flange portion. An end portion of each spoke of the one side element is tied to the end portion of an aligned spoke of the other side element adjacent to the sidewall to restrict the tied end portions from moving away from each other.

Abstract: Provided are universal grip systems and method of using universal grip systems to test coupons. According to various examples, a universal grip system includes two grips and two guide posts for supporting the two grips and allowing the two grips to move with respect to each other. Each grip may include one or two wedges. The wedges are used to engage the coupons during testing and provide anti-buckling support and/or anti-rotation support. The wedges are slidably coupled within corresponding grips, which allows the universal grip system to engage and disengage the coupons by moving one grip with respect to another. The grips may be constructed from thermally neutral materials, such as invar 36. The grips may thermally isolated from the guide posts by, for example, a set of spacers disposed between the grips and linear bearing slidably coupled to the guide posts.

Abstract: In accordance with the present invention an aircraft stringerless fuselage structure is provided comprising an impact compliant outer skin having a plurality of resin impregnated skin fibers forming an outer skin surface, an inner stringerless skin surface, and a skin thickness. A plurality of stiffeners is included, each comprising a plurality of resin impregnated stiffener fibers integrated into the inner stringerless skin structure. The plurality of resin impregnated skin fibers are not aligned with the plurality of resin impregnated stiffener fibers.

Abstract: Carbon fiber bicycle wheels are formed from parts cut from carbon fiber cloth and then joined together to form a rim, sidewalls, spokes, flanges and a center tunnel on which the flanges are mounted. The parts are then assembled, bonded together, and cured to form a wheel. During assembly, the spokes and the wheel are placed in tension by moving the flanges outwardly on the center tunnel after assembly and then bonding them in place to stiffen and strengthen the wheel. The spokes of the drive side of the rear wheel are specially shaped to accommodate torque transfer forces generated by pedaling.

Abstract: A method is presented. The method comprises identifying a desired shape of a ply on a tool, in which the ply has a fiber orientation; identifying a cut shape for the ply, in which the cut shape is different than the desired shape; cutting a composite prepreg ply to have the cut shape, the composite prepreg ply having the fiber orientation; using a deformable carrier to apply the composite prepreg ply having the cut shape to the tool such that the composite prepreg ply has the desired shape on the tool.

Abstract: A composite laminate comprises a plurality of plies of reinforcing fibers. At least some of the plies have reinforcing fibers oriented at ±? with respect to an axis of primary loading, where ? is between 2 and 12 degrees. At least some of the plies have reinforcing fibers oriented at ±? with respect to the axis of primary loading, where ? is between 50 and 85 degrees.

Abstract: An aerodynamic lift structure comprises unbalanced composite skin that couples twist and bending.

Abstract: A method and apparatus for forming a sandwich structure is presented. A sandwich structure comprises a metallic core layer and a thermoplastic layer on a first side of the metallic core layer. The thermoplastic layer is consolidated against the first side of the metallic core layer.

Abstract: In accordance with the present invention an aircraft stringerless fuselage structure is provided comprising an impact compliant outer skin having a plurality of resin impregnated skin fibers forming an outer skin surface, an inner stringerless skin surface, and a skin thickness. A plurality of stiffeners is included, each comprising a plurality of resin impregnated stiffener fibers integrated into the inner stringerless skin structure. The plurality of resin impregnated skin fibers are not aligned with the plurality of resin impregnated stiffener fibers.