Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A method of fabricating a wind turbine blade tubular spar, wherein the tubular spar extends along a designated axis, is made of reinforced polymer material having fibers arranged in at least two directions, and a polymer matrix incorporating the fibers, and has two caps and two webs; the method including the steps of: molding and cross-linking at least part of a cap or web in composite material; molding and cross-linking an L-shaped structure, which has two opposite parallel flanges, and at least partly incorporates the previously molded, cross-linked cap or web of composite material; repeating the above steps to mold and cross-link a further L-shaped structure; and joining the two cross-linked, L-shaped structures, with the flanges positioned facing in pairs.

Abstract: A method of manufacturing a preform includes forming a sheet-shaped structure made of a reinforcing-fiber base material with reinforcing fibers arranged in a predetermined direction into a shape along a lower mold having a three-dimensional shape with a recessed section by using the lower mold and a plurality of upper molds each having a pressing mechanism, wherein the sheet-shaped structure is placed on the lower mold while at least one spot in the sheet-shaped structure is temporarily pressed with at least one of the upper molds, and at least one spot other than the temporarily pressed spot in the sheet-shaped structure is pressed with another upper mold and, then, a spot which is neither the temporarily pressed spot nor the pressed spot is pressed with yet another upper mold, and the spot which has been temporarily pressed with the upper mold is pressed by a predetermined pressing force.

Abstract: In one example, a method includes mixing a plurality of carbon fibers in a liquid carrier to form a mixture, depositing the carbon fiber mixture in a layer, forming a plurality of corrugations in the carbon fiber layer, and rigidifying the corrugated carbon fiber layer to form a corrugated carbon fiber preform. In another example, a method includes substantially aligning a first ridge on a first surface of a first corrugated carbon fiber preform and a first groove on a first surface of a second corrugated carbon fiber preform, bringing the first surface of the first corrugated carbon fiber preform into contact with the first surface of the second corrugated carbon fiber preform, and densifying the first corrugated carbon fiber preform and the second carbon fiber preform to bond the first corrugated carbon fiber preform and the second carbon fiber preform.

Abstract: The present invention relates to a method of producing a multilayer component comprising the following steps: providing a mat-like multilayer structure which comprises at least two outer layers and a core layer, the core layer being arranged between the two outer layers, the core layer comprising a fibre tangle, which contains a binder material and a reinforcing fibre material, a melting point of the binder material being lower than a melting point of the reinforcing fibre material, placing the multilayer structure in a press, heating the multilayer structure in the press with exposure to pressure, such that the binder material melts, while the reinforcing fibre material retains its fibre structure, resulting in formation of a semi-finished product, lofting the semi-finished product, processing the semi-finished product to yield the multilayer component and cooling the component.

Abstract: Structural members and methods for forming structural members are provided. A structural member includes a body portion and a locally reinforced portion. The body portion is formed from a long fiber thermoplastic material, the long fiber thermoplastic material including a plurality of long fibers dispersed in a thermoplastic resin. The locally reinforced portion is formed from a continuous fiber thermoplastic material overmolded by the long fiber thermoplastic material, the continuous fiber thermoplastic material including a plurality of continuous fibers dispersed in a thermoplastic resin.

Abstract: Included herein are constructional techniques as well as finished goods produced thereby. The techniques described are especially useful in producing curved structures in topographical fashion with cutouts from sheets of thermoplastic composites material.

Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on fibers and on a crosslinkable resin, by continuous winding and superposition of several layers of a tape of reinforcement fibers embedded in a matrix based on a composition comprising a crosslinkable resin. The process comprises from upstream to downstream, the following steps: producing a rectilinear arrangement (12) of reinforcement fibers (11) and conveying this arrangement in a feed direction (F); degassing the arrangement (12) of fibers by the action of a vacuum (13); after degassing, impregnating said arrangement (12) of fibers under vacuum with said resin composition in the liquid state (17); passing the pre-preg thus obtained through a die (20) to make said pre-preg into the form of a tape (21) composed of reinforcement fibers (11) in their liquid resin (17) matrix, the thickness of said tape being less than 0.

Abstract: A manufacturing procedure of a composite material part (11), with an edge region (13) destined to be joined to another part by rivets, making a change in the geometry of said edge region (13) with respect to an initial surface (41) on the part's external face, comprising the following steps: a) providing a laying-up tool incorporating a modified surface (43) according to said change in the edge region (13) geometry; b) providing the composite material plies needed for the laying-up of the part, with the plies (51, 51?, . . . , 51n) destined for the edge region (13) of the part affected by the geometric modification being already cut so that they finish as they reach said modified surface (43); c) laying-up said plies over said tool and curing the resultant laminate. The invention also refers to a lower skin of an aircraft wing (11) manufactured according to said procedure.

Abstract: A method for making a wind turbine member wherein a plurality Of components are arranged in a mold. The inner side of the mold determines a surface of the wind turbine member. The components are connected to one another. At least one of the components is a prefabricated structural element which has a fixed geometry with an outer surface. The prefabricated structural element has a positioning projection protruding out of the outer surface and the mold has, on its inner side, a positioning receptacle. The positioning projection is inserted positively into the positioning receptacle to determine the disposition of the prefabricated structural element in the mold.

Abstract: The present invention regards a fibre-reinforced composite moulding with an outer (102) structure and an inner structure (106), wherein the outer structure (102) is formed from at least one layer of fibrous reinforcing material and a cured first resin material, and the inner structure (106) is formed from a plurality of layers of fibrous reinforcing material and a second cured resin material, wherein the viscosity of the uncured first resin material is lower than the viscosity of the uncured second resin material and wherein in the composite moulding the two cured resin materials are at least partially mixed with each other. It also regards a process for the production of such a fibre-reinforced composite moulding.

Abstract: A process for continuous production of profile components of fiber composite material by a forming chain system, an associated profile component and the chain system for its continuous production. The method draws on the forming chain system having at least one forming chain. Here, preform batch of fiber strands, impregnated with matrix material and/or woven fiber webs, knit webs or nonwoven webs, are brought to the system at the working run of the at least one forming chain and are guided through the forming chain system, forming a continuous profile containing the profile component with a variable cross section over the profile length and/or with a profile longitudinal axis with virtually any desired extent. The profile components can be provided with local reinforcements, add-on parts of inserts, for example, for introducing force, as early as during primary forming.

Abstract: A composite laminate includes a plurality of sheets of prepreg stacked one over another, and a scrim layer provided on an exterior surface of the sheets of prepreg. Each prepreg sheet is formed of fibers preimpregnated with resin. The scrim layer and the sheets of prepreg form a composite laminate whereby the scrim layer constitutes an outer, exposed surface of the composite laminate. The scrim layer may be a nonwoven carbon or glass fiber scrim that has absorbed resin from the sheets of prepreg. A method of making a composite laminate includes placing into a mold a scrim and a plurality of sheets of prepreg, with the scrim extending between an exterior surface of the sheets of prepreg and an inner surface of the mold; forming a composite laminate whereby the scrim is adhered to the sheets of prepreg; and removing the composite laminate from the mold. An outer layer of the composite laminate includes the scrim.

Abstract: The invention relates to a structural frame made from a composite material. The purpose of the invention is to obtain a structural frame with high mechanical performances while remaining simple in construction. This purpose is achieved in arranging sets of single-directional fibers in the main part of the structural frame at a predetermined angle. This system may be used as a structural frame particularly for an aircraft fuselage.

Abstract: Composite prepreg is laid up over a tool by placing prepreg material on a carrier film and using the carrier film to apply the prepreg material to the tool. The prepreg is conformed to contours of the tool by deforming the carrier film.

Abstract: The disclosure is generally directed to a modified blade stiffener having enhanced mechanical properties. An illustrative embodiment of the modified blade stiffener includes a stiffener-forming material shaped into a pair of coupled blades having first and second ends, a filler cavity provided at the first end of the blades, a blade filler provided in the filler cavity and a pair of blade flanges provided at the second end of the blades.

Abstract: A fiber composite component comprising at least two, first and second partial elements bordering one another, each having a fiber structure and different matrix systems which respectively embed the fiber structure and cure differently from a liquid state is produced by liquifying the matrix system of the first partial element so that it either penetrates irregularly into the region of the bordering second partial element or leaves an unwetted region in the first partial element adjacent the second partial element, and subsequently liquifying the matrix system of the second partial element so that it can be cured abutting the irregular boundary surfaces of the matrix system of the first partial element. The intermeshing or interlocking of the matrix systems with one another and the fibers increase shear strength.

Abstract: The present invention provides apparatus and methods for growing fullerene nanotube forests, and forming nanotube films, threads and composite structures therefrom. In some embodiments, an interior-flow substrate includes a porous surface and one or more interior passages that provide reactant gas to an interior portion of a densely packed nanotube forest as it is growing. In some embodiments, a continuous-growth furnace is provided that includes an access port for removing nanotube forests without cooling the furnace substantially. In other embodiments, a nanotube film can be pulled from the nanotube forest without removing the forest from the furnace. A nanotube film loom is described. An apparatus for building layers of nanotube films on a continuous web is described.

Abstract: A method for manufacturing a lightweight structural trim part is comprising the following steps: (A) inserting a plurality of layers into a molding tool comprising a first molding half (6) and a second molding half (7). The second molding half (7) comprises a plurality of cup-like indentation (8). The plurality of layers at least comprises a first air permeable skin layer (1) facing the first molding half (6), a second air tight skin layer (3,4) facing the second molding half (7), and a film layer (2) between the two skin layers. (B) Closing the molding tool and discharging gas from one side in order to press the first skin layer against the first molding half. (C) Shaping and consolidating the first porous skin layer. (D) Charging with pressurized air the first space in order to press the second skin layer against the second molding half. (E) Shaping and consolidating the second skin layer.

Abstract: Method of manufacturing a fiber-reinforced composite molding, the method comprising the steps of: (a) disposing at least one layer of fibrous reinforcing material within a mold; (b) disposing at least one pre-preg layer adjacent to the fibrous reinforcing material, the pre-preg layer comprising fibrous reinforcement at least partially impregnated with uncured first resin material, to form a laminar assembly of the at least one layer of fibrous reinforcing material and the at least one pre-preg layer within the mold; (c) applying a vacuum to the assembly; (d) infusing a flowable uncured second resin material, under the vacuum, into the at least one layer of fibrous reinforcing material; and (e) curing the first and second resin materials at least partially simultaneously to form the fiber-reinforced composite molding which comprises at least one first structural portion formed from the fibrous reinforcement and the cured first resin material bonded to at least one second structural portion formed from the at l

Abstract: A process for manufacturing a curved structural part includes fabricating a mold of the curved structural part having at least two faces that form a male mold section between a minimum radius of curvature of the curved structural part and another radius of curvature belonging to one of the two faces, preparing a stack of multidirectional fibers of one or more fiber plies oriented ±? or 90° in relation to a longitudinal direction of the curved structural part, cutting a first multidirectional strip in the stack extending longitudinally and having a width at least equal to a maximum width of the curved structural part, applying the first multidirectional strip over the mold to gradually conform the first multidirectional strip to the mold, applying the first multidirectional strip on the face having the minimum radius of curvature, and pressing and tightening the first multidirectional strip over the other faces.

Abstract: A patch for reworking an inconsistent area in a composite structure includes a composite laminate patch adapted to cover the inconsistent area and bonded to the structure by a layer of adhesive. The patch includes a plurality of composite plies having a tapered cross section, and at least first and second regions respectively having differing fracture toughnesses.

Abstract: An air filter arrangement is disclosed. The air filter arrangement includes media comprising corrugated media secured to facing media and forming inlet and outlet flutes secured to one another. Media pack arrangements including such media are described. Also described are filter cartridges including such media packs and air cleaners including the filter cartridges. Advantageous housing seal arrangements having a pinch seal member and forming a trough are described. Methods of assembly and use are also provided. Also, systems of use are described.

Abstract: A former for fabricating a gas composite material casing for a gas turbine, which is obtained by forming fiber reinforcement as superposed layers of a fiber texture and densifying the fiber reinforcement with a matrix, is disclosed. The former has two cheekplates and an annular wall with an outside surface presenting a profile that corresponds to the profile of the inside surface of the casing that is to be fabricated. The annular wall of the former includes a removable fastener device for fastening a fiber texture layer and serving to hold the first layer of the fiber texture mechanically while the fiber texture is being wound on the former.

Abstract: It is intended to provide a method and an apparatus for manufacturing a fiber-reinforced base material, which is capable of manufacturing a fiber-reinforced base material of high quality while preventing generation of defects such as wrinkles during stacking of the base material sheet. The method for manufacturing the fiber-reinforced base material formed by stacking a base material sheet including a reinforcement fiber onto a mold having a double-curved surface shape, includes steps of: supplying the base material sheet onto the mold from a base material roll while applying distribution varying in a width direction (X direction) to a length of the base material sheet in a sheet-supplying direction of the base material sheet (Y direction) in correspondence with the double-curved surface shape of the mold; and applying pressure to the base material sheet in contact with the mold.

Abstract: A helmet shell formed from two types of high tenacity fibers in multiple layers of fibrous materials. The fibrous materials are in the form of layers of fibrous networks in a resin matrix. There are a plurality of each type of fibrous layers. Preferably the outer set of fibrous layers is formed from aramid fibers and the inner set of fibrous layers is formed from high tenacity polyolefin fibers. There may also be employed a third type of fibrous material as an additional set of fibers and used as the outer layers of the helmet shell. The third type of fibrous layers is formed from glass fibers that are also in a resin matrix. The helmet is lightweight, has excellent ballistic resistant properties and is useful for both military and non-military applications.

Abstract: The invention relates to a fire-resistant component (1) which satisfies the requirements of at least class B-15. Such components are known per se and are manufactured as insulated steel structures. In order that the component (1) can be manufactured more easily and with greater versatility in the manner of glass-fibre-reinforced plastic, it is proposed that it is manufactured with multiple layers of phosphate ceramic and also of fibres (7, 8, 9), and that a layer structure of the component (1) comprises at least one layer (4), on the surface thereof which faces towards a potential heat source, which is joined together only partially with a layer (5) arranged thereunder, i.e. remote from the heat source. The invention also relates to a process for producing such a component.

Abstract: A method of manufacturing a component from a composite-fiber-material semifinished product includes providing a forming support having a contour including at least one section corresponding to a surface of the manufactured component. The semifinished product is placed onto the forming support and the semifinished product is formed such that the semifinished product contacts the forming support. Further, a device form manufacturing component includes the forming support having the contour including at least one section corresponding to the surface of the manufacture component.

Abstract: A method for manufacturing a fibre reinforced composite is provided. Fibre material is connected together by a thread, wherein the thread has material which at least partly degrades before the manufacturing of the fibre reinforced composite is finished.

Abstract: A composite fabric product comprises at least one layer of textile material and at least one layer of melted plastic material, wherein non-melting textile material is embedded in at least one of the said layers of melted plastic material, and wherein filaments or yarns located in at least one of said layers of textile material extend into said at least one layer of melted plastic material and interlace with the non-melting textile material embedded therein.

Abstract: Method for manufacturing a composite fiber component (1) the method comprising the following method steps: forming a moulding core (4) comprising a hollow profile (15) made of segments (16a . . . d) in order to establish an external geometry of the moulding core (4), wherein the segments (16a . . . d) of the moulding core (4) each extend in the direction of the longitudinal axis of the moulding core (4) and are each constructed so as to be pivotable about an axis running in the longitudinal direction of the moulding core (4), between a folded position (A), and an unfolded position (B) of the hollow profile (15) of the moulding core (4), wherein the segments (16a . . . d) are constructed so as to be coupled to one another via connections (18a . . . d, 19a . . .

Abstract: A method for making parts with variable thickness corners and parts with variable thickness corners are disclosed. The method includes laying up multiple plies to form a tailored blank, associating the blank with a convex and concave die, and applying pressure and heat so that material from at least one of the plies migrates towards a voided corner area formed between the dies.

Abstract: A process for the production of a structural part of an aircraft, whereby the part is made of composite material that includes a thermosetting resin and that has a section profile that can be stamped, whereby the process includes: producing a flat blank by draping layers of supports that are preimpregnated with thermosetting resin, partially cross-linking the flat blank, and stamping the flat blank between a matrix (14) and a punch (16) that are called the equipment, each including an impression that is adapted to the shape of the surface that is in contact with the part that is to be produced and whose air gap is sized based on the part that is to be produced, wherein the equipment is heated to modulate the progress of the cross-linking at the end of the forming operation.

Abstract: The invention relates to a device for producing a toroid-shaped fiber composite product. The device comprises at least two fiber or fiber composite material dispensing units (2, 3), the dispensing units being adapted to place a fiber (4) or a fiber composite material onto the surface of a toroid-shaped mandrel (5); positioning means to effectuate relative movement of the mandrel and the dispensing units during placement of the fiber or fiber composite material. The invention further relates to a method for producing a toroid-shaped fiber composite product, preferably with a concave cross-section, in particular the rim of a bicycle wheel. The method comprises providing a toroid-shaped mandrel, dispensing fibers or fiber composite material from at least two dispensing units, placing the fibers or fiber composite material onto the mandrel while effectuating a relative movement of the mandrel and the dispensing units, and reshaping at least part of the mandrel, preferably by thermoforming.

Abstract: A molding tool for manufacturing a fiber-reinforced plastic aerodynamic aircraft component, which aircraft component, in order to form several bays arranged on the inside and delimited by an outer skin and spars arranged spaced apart from each other, in each case includes a multi-part mold core that matches the shape of the respective bay, wherein to conform to local skin reinforcements and/or spar reinforcements that extend into at least one of the bays, the multi-part mold core includes four or five core parts, of which two core parts comprising a triangular cross section are arranged along opposing edges of the bay, which edges interact with two or three core parts that fill the space between the two triangular core parts, which space extends diagonally relative to the bay.

Abstract: Polymer articles are often reinforced by addition of fibers which may be assembled into a structured reinforcement such as a woven mat or sheet and the mat or sheet serves as the reinforcement. Such woven fiber-reinforced polymer composite articles may exhibit undesirable variations in surface height which mimic the geometry of the underlying reinforcements, a phenomenon known as print through. By forming, on the surface of the article, a relatively thin, layer of a compatible polymer incorporating closely-spaced, short, carbon nanotubes more or less uniformly dispersed throughout the layer and oriented normal to the article surface, print through may be reduced or eliminated. Methods for fabricating such an article are detailed.

Abstract: The present invention is a method for producing a fiber-reinforced plastic molding including, in the following order, the steps of: forming a preform laminate (5b) fixed to a molding die (6) by laminating a plurality of preforms (5a) each including a dry fiber fabric (4) and a fixing resin (2), the preforms being laminated through the fixing resin (2) formed on a surface of the dry fiber fabric and including a partially-cured thermosetting resin exhibiting tackiness at a room temperature; impregnating the dry fiber fabric (4), provided in the preform laminate (5b) fixed to the molding die (6), with a liquid thermosetting resin (11); curing the liquid thermosetting resin (11) and the fixing resin (2) to form a fiber-reinforced plastic molding; and demolding the fiber-reinforced plastic molding from the molding die (6).

Abstract: A system and method for the production of cellular materials. Several geometries such as honeycomb, chiral, auxetic are described. The pre-formation of the cellular structure is by penetration of a reinforcement fabric by means of punches properly structured. Punches housed on one of the matrices of the device allow obtaining several geometries without need of complex fabric pre-formations operations or of manual placement of the fabric in the interstices of the mold.

Abstract: The integral layer provides a ductile interface for attachment locations of a turbine engine component where a metallic surface is adjacent the attachment location. The ductile layer provides a favorable load distribution through the composite at the attachment location, and eliminates the need for a metallic shim.

Abstract: A composite gas turbine engine structure includes a retention ring with airfoils mounted on, integral with, and extending radially away from retention ring. Retention ring includes annular composite plies, a circumferentially segmented airfoil ring including airfoil ring segments disposed around one of outer and inner circumferences of retention ring. Airfoil ring segments include annular bases and radially extending clockwise and counter-clockwise airfoil segments at clockwise and counter-clockwise ends of annular base. Composite airfoils include circumferentially adjacent ones of the clockwise and counter-clockwise airfoil segments. A flowpath shell circumferentially disposed around segmented airfoil ring traps annular bases between flowpath shell and retention ring. Composite airfoils airfoils extend through slots in flowpath shell. Plies may be wrapped in a single spiral made from a continuous composite tape. Slots may be circumferentially angled.

Abstract: A vacuum interrupter embedded in an insulating material is disclosed, the insulating material including a first main layer having a first sub-layer, a second sub-layer, and a third sub-layer. The second sub-layer is arranged between the first sub-layer and the third sub-layer. The first sub-layer, the second sub-layer, and the third sub-layer can include fibers, wherein the first sub-layer can include a group of first fibers which are arranged in parallel with respect to each other.

Abstract: A hollow golf club head with a concave portion is disclosed and claimed. The club head includes a metallic portion and a light-weight portion, which may be formed of plastic, composite, or the like. The concave portion allows the club designer to make a club head having very thin portions while still maintaining the requisite structural integrity. Convex bulges may optionally be provided to house weight inserts to enhance the playing characteristics of the golf club. The metallic portion of the club head may take on the appearance of a frame, into which several light-weight inserts are positioned. These light-weight inserts may be positioned in the crown, skirt, and sole of the club head. The club head may be formed by co-molding, eliminating the need for welding or adhesives, freeing mass to be used in more beneficial ways. The club head may be large to increase playability and forgiveness.

Abstract: The present invention relates to a method for making a preform (1) for a composite with a thermoplastic matrix, said preform (1) comprising one or several layers of reinforcement fibers (3) sewn on a support (2) by means of at least one attachment yarn (4)and according to the TFP process, characterized in that the method comprises one or several steps for depositing a thermoplastic-resin layer (5a,5b) on the support (2) or on a layer (3) of reinforcement fibers.

Abstract: Methods and apparatus for manufacturing an FC parison out of a laminate with at least two prepreg layers provide for: mounting at least a first edge section of the laminate in a first clamping device that can be moved relative to a fitting by means of a mechanical gearing, and a second edge section of the laminate lying opposite the first edge section in another clamping device, exerting a tensile stress via the first clamping device relative to the second clamping device over the area of the laminate lying between the clamping devices, while simultaneously moving the first clamping device in a direction directed away from the second clamping device up to a location where a rounded surface area of a fitting imparts to the laminate a curvature between the first clamping device and second clamping device as viewed in its longitudinal direction.

Abstract: A method for manufacturing composite parts. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool for a composite part. The inner mold line tool may be positioned with the composite part inside an outer mold line tool. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. The inner mold line tool and the temporary removal layer may be removed from inside of the outer mold line tool after transferring the composite part and the temporary removal layer to the outer mold line tool.

Abstract: There is provided an underwire for a brassiere. In a first embodiment, the underwire is made of two or more different materials. In a second embodiment, one end of the underwire is tapered. A method of manufacturing the underwire and a mold for manufacturing the underwire are also provided.

Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, ?45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.

Abstract: A composite sporting implement, such as a ball bat or bat barrel, is formed with layers of continuous structural fibers embedded in a binder material having a high melting point. Such a binder does not undergo a chemical conversion process during forming of the ball bat. The layers are shaped into a preform and placed in a mold. Heat and pressure are applied to bring the binder to its melting point and to cause the binder material to flow between adjacent layers. The mold is then cooled below the binder's melting point to solidify the composite structure. A composite sporting implement formed in this manner exhibits excellent shear strength, toughness, and damping qualities.

Abstract: Method of manufacturing aerogenerator blades that avoids or reduces some formation deficiencies existing in the traditional methods of manufacturing aerogenerator blades. The method comprises: positioning at least one support plate (2) on a plug (3) corresponding to a predetermined shape of at least a portion of the blade; removably fixing the support plate (2) to the plug (3); stacking a plurality of layers (1) of at least one material over the support plate (2); stitching the plurality of layers (1) to the support plate (2); displacing the plurality of layers (1) stitched to the support plate (2) into a mold (4), the mold (4) having a shape corresponding to the counter shape of the plug (3).

Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.