Abstract: The present disclosure relates to inserts for use with sandwich panels, such as composite panels, and related methods. Presently disclosed inserts may include a retention feature and/or an anti-rotation feature that may be configured to retain the insert in place within a bore formed in the sandwich panel. In this manner, presently disclosed inserts may be secured without the use of adhesive compounds, which may increase efficiency and/or reduce costs in manufacturing apparatus that include one or more sandwich panels having one or more inserts placed therein. Presently disclosed methods of installing an insert into a sandwich panel may include rotating the insert with respect to the sandwich panel as the insert is installed, such that a portion of the insert may be positioned under the skin of the sandwich panel (e.g., a portion of the insert may be positioned between the skin and the core of the sandwich panel).

Abstract: A panel system includes a tab panel having at least one tab extending therefrom. The tab panel has a core and a facesheet adjacent the core. The panel system includes a slot panel having at least one slot receiving the corresponding tab of the tab panel therein. The slot panel has a core and a facesheet adjacent the core. The panel system includes a clip positioned between the tab panel and the slot panel. The clip is at least partially received in the slot. The clip has a tab panel securing member being secured to the tab panel and the clip has a slot panel securing member being secured to the slot panel. The clip securely joins the tab panel to the slot panel.

Abstract: The present disclosure relates to inserts for use with sandwich panels, such as composite panels, and related methods. Presently disclosed inserts may include a retention feature and/or an anti-rotation feature that may be configured to retain the insert in place within a bore formed in the sandwich panel. In this manner, presently disclosed inserts may be secured without the use of adhesive compounds, which may increase efficiency and/or reduce costs in manufacturing apparatus that include one or more sandwich panels having one or more inserts placed therein. Presently disclosed methods of installing an insert into a sandwich panel may include rotating the insert with respect to the sandwich panel as the insert is installed, such that a portion of the insert may be positioned under the skin of the sandwich panel (e.g., a portion of the insert may be positioned between the skin and the core of the sandwich panel).

Abstract: The present disclosure relates to inserts for use with sandwich panels, such as composite panels, and related methods. Presently disclosed inserts may include a retention feature and/or an anti-rotation feature that may be configured to retain the insert in place within a bore formed in the sandwich panel. In this manner, presently disclosed inserts may be secured without the use of adhesive compounds, which may increase efficiency and/or reduce costs in manufacturing apparatus that include one or more sandwich panels having one or more inserts placed therein. Presently disclosed methods of installing an insert into a sandwich panel may include rotating the insert with respect to the sandwich panel as the insert is installed, such that a portion of the insert may be positioned under the skin of the sandwich panel (e.g., a portion of the insert may be positioned between the skin and the core of the sandwich panel).

Abstract: A panel system includes a tab panel having at least one tab extending therefrom. The tab panel has a core and a facesheet adjacent the core. The panel system includes a slot panel having at least one slot receiving the corresponding tab of the tab panel therein. The slot panel has a core and a facesheet adjacent the core. The panel system includes a clip positioned between the tab panel and the slot panel. The clip is at least partially received in the slot. The clip has a tab panel securing member being secured to the tab panel and the clip has a slot panel securing member being secured to the slot panel. The clip securely joins the tab panel to the slot panel.

Abstract: A method to cast in place an internally threaded hole in an open cell core of a sandwich structural composite panel enables a threaded fastener to be secured to the sandwich structural composite panel without requiring a separate insert for the fastener.

Abstract: A panel system includes a tab panel having at least one tab extending therefrom. The tab panel has a core and a facesheet adjacent the core. The panel system includes a slot panel having at least one slot receiving the corresponding tab of the tab panel therein. The slot panel has a core and a facesheet adjacent the core. The slot is formed in the facesheet and at least a portion of the core. The panel system includes a clip positioned between the tab panel and the slot panel. The clip is at least partially received in the slot. The clip has a tab panel securing member being secured to the tab panel and the clip has a slot panel securing member being secured to the slot panel. The clip securely joins the tab panel to the slot panel.

Abstract: An auxiliary milling unit configured to be coupled to a movable main milling unit of a milling machine includes an auxiliary milling tool and a mounting portion configured to couple the auxiliary milling unit to the main milling unit. The mounting portion is movable with the main milling unit. An auxiliary movement assembly is coupled to the mounting portion and the auxiliary milling tool. The auxiliary movement assembly is movable relative to the mounting portion to move the auxiliary milling tool relative to the main milling unit.

Abstract: The present disclosure relates to inserts for use with sandwich panels, such as composite panels, and related methods. Presently disclosed inserts may include a retention feature and/or an anti-rotation feature that may be configured to retain the insert in place within a bore formed in the sandwich panel. In this manner, presently disclosed inserts may be secured without the use of adhesive compounds, which may increase efficiency and/or reduce costs in manufacturing apparatus that include one or more sandwich panels having one or more inserts placed therein. Presently disclosed methods of installing an insert into a sandwich panel may include rotating the insert with respect to the sandwich panel as the insert is installed, such that a portion of the insert may be positioned under the skin of the sandwich panel (e.g., a portion of the insert may be positioned between the skin and the core of the sandwich panel).

Abstract: A method to cast in place an internally threaded hole in an open cell core of a sandwich structural composite panel enables a threaded fastener to be secured to the sandwich structural composite panel without requiring a separate insert for the fastener.

Abstract: A panel system includes a tab panel having at least one tab extending therefrom. The tab panel has a core and a facesheet adjacent the core. The panel system includes a slot panel having at least one slot receiving the corresponding tab of the tab panel therein. The slot panel has a core and a facesheet adjacent the core. The slot is formed in the facesheet and at least a portion of the core. The panel system includes a clip positioned between the tab panel and the slot panel. The clip is at least partially received in the slot. The clip has a tab panel securing member being secured to the tab panel and the clip has a slot panel securing member being secured to the slot panel. The clip securely joins the tab panel to the slot panel.

Abstract: An auxiliary milling unit configured to be coupled to a movable main milling unit of a milling machine includes an auxiliary milling tool and a mounting portion configured to couple the auxiliary milling unit to the main milling unit. The mounting portion is movable with the main milling unit. An auxiliary movement assembly is coupled to the mounting portion and the auxiliary milling tool. The auxiliary movement assembly is movable relative to the mounting portion to move the auxiliary milling tool relative to the main milling unit.

Abstract: An apparatus for forming a bend in a composite panel is provided. An angle and a radius bend are identified for a bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2?*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA?2K(R?T), wherein K is Tan(A/2) and T is a thickness of the composite panel.

Abstract: An apparatus for forming a bend in a composite panel is provided. An angle and a radius bend are identified for a bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2?*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA?2K(R?T), wherein K is Tan(A/2) and T is a thickness of the composite panel.

Abstract: A method for forming a bend in composite panel. In one advantageous embodiment, a method is used to form a bend in a composite panel. An angle and a radius bend are identified for the bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2?*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA?2K(R?T), wherein K is Tan(A/2) and T is a thickness of the composite panel. The composite panel with the slot is bent to form the bend.

Abstract: A method and apparatus for forming a bend in composite panel. In one advantageous embodiment, a method is used to form a bend in a composite panel. An angle and a radius bend are identified for the bend. A location of the bend in the composite panel is identified. A slot is cut having a curved flange in the composite panel at the identified location in a single pass through the composite panel with a tool, wherein the curved flange has a shape with a bend allowance width and a bend slot width. The bend allowance width is BA=2?*A/360, wherein BA is the bend allowance width, R is a corner radius, and A is a bend angle. The bend slot width is BS=BA?2K(R?T), wherein K is Tan(A/2) and T is a thickness of the composite panel. The composite panel with the slot is bent to form the bend.