Abstract: A unitary core panel for a composite sandwich structure includes a plurality of cell walls defining a plurality of core cells, the plurality of cell walls extending across a thickness of the core, the plurality of core cells including one or more defined structural nonuniformities resulting in nonuniform properties of the core panel. A method of forming a core panel for a composite sandwich structure includes determining structural requirements of the core panel, designing the core panel to satisfy the structural requirements with one or more local nonuniformities in the core panel, and manufacturing the core panel as a unitary core panel with the one or more local nonuniformities.

Abstract: A unitary core panel for a composite sandwich structure includes a plurality of cell walls defining a plurality of core cells, the plurality of cell walls extending across a thickness of the core, the plurality of core cells including one or more defined structural nonuniformities resulting in nonuniform properties of the core panel. A method of forming a core panel for a composite sandwich structure includes determining structural requirements of the core panel, designing the core panel to satisfy the structural requirements with one or more local nonuniformities in the core panel, and manufacturing the core panel as a unitary core panel with the one or more local nonuniformities.

Abstract: A unitary core panel for a composite sandwich structure includes a plurality of cell walls defining a plurality of core cells, the plurality of cell walls extending across a thickness of the core, the plurality of core cells including one or more defined structural nonuniformities resulting in nonuniform properties of the core panel. A method of forming a core panel for a composite sandwich structure includes determining structural requirements of the core panel, designing the core panel to satisfy the structural requirements with one or more local nonuniformities in the core panel, and manufacturing the core panel as a unitary core panel with the one or more local nonuniformities.

Abstract: An armor panel includes a multiple of pins which penetrate a first skin, a high molecular weight polyethylene fiber composite material layer and a second skin which integrates ballistic protection into load bearing structure.

Abstract: A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

Abstract: An armor system which integrates ballistic protection into load bearing structure. Each armored panel is manufactured as a sandwich structure having a multiple of layers including a hard ballistic material layer of a Ceramic/CMC hybrid armor material capable of defeating high velocity Armor Piercing projectiles.

Abstract: An aircraft floor system includes a composite panel which generally includes an inboard layer, an inboard interlock layer, a core layer, an outboard interlock layer and an outboard layer. The advanced sandwich core material may include K-Cor™ or X-Cor™ which is pinned through at least one ply of dry composite reinforcement to provide a mechanical lock between the pins and an inboard and outboard interlock layer. Bonding of the locked-in ply with the inboard and outboard results in improved structural performance and damage tolerance.

Abstract: An armor system which integrates ballistic protection into load bearing structure. Each armored panel is manufactured as a sandwich structure having a multiple of layers including a hard ballistic material layer of a Ceramic/CMC hybrid armor material capable of defeating high velocity Armor Piercing projectiles.

Abstract: An armor panel includes a multiple of pins which penetrate a first skin, a high molecular weight polyethylene fiber composite material layer and a second skin which integrates ballistic protection into load bearing structure.

Abstract: A thermoplastic matrix airframe structure section includes a multitude of thermoplastic matrix frame members and a multitude of thermoplastic matrix beam members which form a substructure, which receives a thermoplastic matrix inner cap grid structure, a thermoplastic matrix outer cap grid structure, and a thermoplastic matrix skin which are in-situ co-bonded to the substructure to significantly strengthen and unify the substructure.

Abstract: An aircraft floor system includes a composite panel which generally includes an inboard layer, an inboard interlock layer, a core layer, an outboard interlock layer and an outboard layer. The advanced sandwich core material may include K-Cor™ or X-Cor™ which is pinned through at least one ply of dry composite reinforcement to provide a mechanical lock between the pins and an inboard and outboard interlock layer. Bonding of the locked-in ply with the inboard and outboard results in improved structural performance and damage tolerance.

Abstract: A composite transmission housing includes resin transfer molding or vacuum assisted resin transfer molding manufacturing processes combined with discontinuous fiber preforms. The preforms are assembled in a prepared injection and cure mold with additional details and fillers. The preforms are constructed such that the preforms are assembled into the mold in a specific order to assure proper arrangement. Using a combination of vacuum and pressure, a resin is injected into the mold to completely infuse the assembled preforms. At completion, the mold is heated to the resin cure temperature and held at this temperature for sufficient time to insure complete cure.

Abstract: A composite material has a foam core having first and second faces. A plurality of fibrous pins have first end portions protruding from the core first face. A first face sheet is secured to the core first face. The first face sheet comprises, in major part, one or more non-woven, non random, fiber layers. The pin first end portions protrude into the first face sheet.

Abstract: The composite molding apparatus includes a rigid base member and a complementary semi-rigid mold member or “black bag” caul plate having a sieve member formed therein. The sieve member layer of the semi-rigid mold member engages pins which extend from the sandwich core to limit penetration into the semi-rigid mold member to a predetermined depth. The semi-rigid mold member is supported relative to the rigid mold member by the pins to provide uniform pressure transfer to the composite article during a high pressure co-cure molding process without crushing the sandwich core.

Abstract: The composite molding apparatus includes a rigid base member and a complementary semi-rigid mold member or “black bag” caul plate having a sieve member formed therein. The sieve member layer of the semi-rigid mold member engages pins which extend from the sandwich core to limit penetration into the semi-rigid mold member to a predetermined depth. The semi-rigid mold member is supported relative to the rigid mold member by the pins to provide uniform pressure transfer to the composite article during a high pressure co-cure molding process without crushing the sandwich core.

Abstract: A method of fabricating a low total density, stabilized ramped honeycomb core for high pressure co-cure molding of a lightweight honeycomb core composite article includes forming the honeycomb core by net shaping stabilized honeycomb core material into a ramped honeycomb core. The ramped honeycomb core is prepared for lay-up and co-cure by applying a layer of low areal weight film adhesive to the upper and lower surfaces and to each ramped surface of the ramped honeycomb core. The honeycomb core material is stabilized for the net shaping operation by applying a layer of low areal weight film adhesive to the upper and lower surfaces of the honeycomb core material in a predetermined picture frame format.

Abstract: A method for high pressure co-cure molding of lightweight honeycomb core composite articles having ramped surfaces utilizing low total density, stabilized ramped honeycomb cores. The low total density, stabilized ramped honeycomb core is formed by net shaping stabilized honeycomb core material into a ramped honeycomb core, which is prepped for lay-up and co-cure by applying a layer of low areal weight film adhesive to the upper, lower and ramped surfaces thereof. The honeycomb core material is stabilized for the net shaping operation by a layer of the low areal weight film adhesive applied to the upper and lower surfaces of the material in a predetermined picture frame format. Composite prepregs and the ramped honeycomb core are layed-up in a semi-rigid molding assembly including a rigid base member and a complementary semi-rigid mold member having at least one internal rigid reinforcement insert, which is vacuum bagged and disposed in an autoclave.

Abstract: A simulator dome for a motion base simulator comprises one or more fiber reinforced outer layers, inner layers of a similar material and an intermediate core. The intermediate core is preferably a structural foam of variable density to allow selectively lowering the dome center of gravity to enhance the simulation capabilities of the motion system to simulate various flight maneuvers. By producing the dome from fiber reinforced polymer and using a core of variable density, a dome of unitary construction with no through fasteners is produced, having high strength for withstanding high G maneuvers without cracking or distortion, enhancing simulator effectiveness and increasing the accuracy of the simulated flight conditions.

Abstract: A composite molding apparatus for high pressure co-cure molding of lightweight honeycomb core composite articles having ramped surfaces utilizing low total density, stabilized ramped honeycomb cores. The composite molding apparatus is a semi-rigid molding assembly that includes a rigid base member and a complementary semi-rigid mold member that is formed from a combination of layers of fiber-reinforced elastomeric material and unreinforced elastomeric material. The semi-rigid mold member further includes internal rigid reinforcement inserts formed from a structurally rigid material and having a configuration that matches the configuration of the ramped surfaces of the honeycomb composite article. The rigid reinforcement inserts are interleaved between the layers of fiber-reinforced elastomeric material and/or unreinforced elastomeric material forming the semi-rigid mold member.

Abstract: A simulator dome for a motion base simulator comprises one or more fiber reinforced outer layers, inner layers of a similar material and an intermediate core. The intermediate core is preferably a structural foam of variable density to allow selectively lowering the dome center of gravity to enhance the simulation capabilities of the motion system to simulate various flight maneuvers. By producing the dome from fiber reinforced polymer and using a core of variable density, a dome of unitary construction with no through fasteners is produced, having high strength for withstanding high G maneuvers without cracking or distortion, enhancing simulator effectiveness and increasing the accuracy of the simulated flight conditions.