Abstract: The disclosure describes a device, method, and transfer apparatus for stamping thermoplastic composite blanks. The blanks may consist of laminated fibrous plies which may comprise continuous fibers in a thermoplastic polymer matrix. Supporting unidirectional fibers or holding tapes, pre-impregnated with polymer and extending beyond a shaping area's edges may be clamped in jaws, allowing the blank to be suspended and heated without sagging. The transfer system moves the blank between a heating station and a stamping station, where a punch and die may shape it while maintaining calibrated tension to reduce defects such as creasing or delamination. Advanced jaw mechanisms, including pivoting jaws with multiple clamping slots, enable differential tensioning of plies for precise forming of complex geometries. After stamping, excess fiber extensions may be trimmed and may be recycled. This approach eliminates the need for nonrecyclable polyimide films and improves process reliability for thick or heavy blanks.

Abstract: The disclosure describes a device, method, and transfer apparatus for stamping thermoplastic composite blanks. The blanks may consist of laminated fibrous plies which may comprise continuous fibers in a thermoplastic polymer matrix. Supporting unidirectional fibers or holding tapes, pre-impregnated with polymer and extending beyond a shaping area's edges may be clamped in jaws, allowing the blank to be suspended and heated without sagging. The transfer system moves the blank between a heating station and a stamping station, where a punch and die may shape it while maintaining calibrated tension to reduce defects such as creasing or delamination. Advanced jaw mechanisms, including pivoting jaws with multiple clamping slots, enable differential tensioning of plies for precise forming of complex geometries. After stamping, excess fiber extensions may be trimmed and may be recycled. This approach eliminates the need for nonrecyclable polyimide films and improves process reliability for thick or heavy blanks.

Abstract: The invention pertains to a method for integrating a fitting fitted between two wings of a composite profile comprising the steps of: obtaining a preform of a fitting impregnated with a thermosetting resin, comprising two flanges and a rib; pre-curing the laminate preform of the fitting to obtain a partial polymerization of the preform; laying up a laminate preform of the profile so that fibers impregnated with a thermosetting resin included in two of the wings of the laminate preform of the profile are laid up over the two flanges of the preform of the partially polymerized fitting; and completely polymerizing an assembly comprising the laminate preform of the profile and the laminate preform of the partially polymerized fitting while maintaining into contact the flanges of the laminate preform of the fitting with the wings of the laminate preform of the profile.

Abstract: The invention relates to a fiber layup method comprising preparing a deposition surface (110) of a tooling (100) configured for the fiber layup of a prepreg comprising a thermoplastic polymer matrix, the method comprising steps of: preparing the deposition surface (110); depositing a thin layer (320) of a thermoplastic polymer on at least part of the deposition surface (110) thus prepared; wherein a melting temperature of the thermoplastic polymer of the thin layer is equal to or higher than a melting temperature of the thermoplastic polymer matrix. The invention also relates to a tooling configured to implement such a method).

Abstract: The invention relates to an apparatus for stamping thermoplastic matrix composite blanks, particularly those reinforced with continuous fibers such as carbon or glass. The disclosed apparatus incorporates a stamping device with a movable punch (800) and stamping die (500), a transfer frame (400) supporting a composite stamping blank (200), and a tensioning mechanism that maintains controlled forces on the blank during stamping. The transfer frame comprises at least two holding members (300) that grip the composite blank along its edges (220), ensuring precise positioning and a controlled tension. These holding members (300) cooperate with receiving members (550) attached to the stamping die, in retaining assemblies, firmly gripping edges of the blank while allowing guided translation and pivoting motions, setting a tension in the blank that prevent wrinkles appearance.

Abstract: The invention pertains to a composite part with a fibrous reinforcement and a thermoplastic polymer matrix, comprising: substrate part with a matrix of a first thermoplastic polymer having a first melting temperature; stiffener made of a composite material with a matrix of a second thermoplastic polymer having a second melting temperature; comprising the steps of: obtaining an unconsolidated preform of the substrate part; obtaining a preform of the stiffener; integrating a layer of the first thermoplastic polymer into the preform of the stiffener at a location configured to be in contact with the substrate part; and subjecting the substrate part and the preform of stiffener to a thermomechanical cycle so as to consolidate the substrate part and weld the stiffener to the substrate part.

Abstract: The invention relates to a tooling for stamping a composite blank with a thermoplastic matrix and continuous fibrous reinforcement, and a stamping method using such a tooling, the tooling comprising: a die comprising an imprint (110) having a bottom (111) and side walls (112); a punch (120) the external shape of which is paired with the imprint of the die and comprising a central part (123) and at least two lateral movable parts (121, 122) in sliding connection with the central part (123), so that the movable lateral parts being stopped in translation according to a striking direction (190) against the bottom of the die, a further displacement of the central part (123) in the same direction causes the movable lateral parts to move in translations perpendicular to the striking direction (190).

Abstract: An engine pylon rear secondary structure for an aircraft comprising an engine pylon (30) suspending an engine (20) to a wing (10), the engine pylon rear secondary structure comprising: a front attachment interface (310); an aft attachment interface (320); a composite beam (301) connecting the front attachment interface (310) and the aft attachment interface (320); the composite beam (301) comprising a first section (501) and a second section (502) integral with the first section; frames (330) configured for supporting fairing panels (340) and being attached to the first section (501) of the composite beam; and fairing panels (340) attached to outer faces of the frames; wherein the composite beam is of a U-shaped cross-section, the frames (330) comprising three brackets (431, 432, 433) configured to be attached to the composite beam on three external faces of the U-shaped cross-section.

Abstract: An engine pylon rear secondary structure for an aircraft comprising an engine pylon (30) suspending an engine (20) to a wing (10), the engine pylon rear secondary structure comprising: a front attachment interface (310); an aft attachment interface (320); a composite beam (301) connecting the front attachment interface (310) and the aft attachment interface (320); the composite beam (301) comprising a first section (501) and a second section (502) integral with the first section; frames (330) configured for supporting fairing panels (340) and being attached to the first section (501) of the composite beam; and fairing panels (340) attached to outer faces of the frames; wherein the composite beam is of a U-shaped cross-section, the frames (330) comprising three brackets (431, 432, 433) configured to be attached to the composite beam on three external faces of the U-shaped cross-section.

Abstract: The invention pertains to a composite part with a fibrous reinforcement and a thermoplastic polymer matrix, comprising: substrate part with a matrix of a first thermoplastic polymer having a first melting temperature; stiffener made of a composite material with a matrix of a second thermoplastic polymer having a second melting temperature; comprising the steps of: obtaining an unconsolidated preform of the substrate part; obtaining a preform of the stiffener; integrating a layer of the first thermoplastic polymer into the preform of the stiffener at a location configured to be in contact with the substrate part; and subjecting the substrate part and the preform of stiffener to a thermomechanical cycle so as to consolidate the substrate part and weld the stiffener to the substrate part.

Abstract: A leading edge slat of a wing element of an aircraft. The aircraft defining a mark including a main fuselage axis x and a spanwise axis y. The wing procuring a lift along an axis z. The wing element having a skin forming the leading edge slat, a spar linked to the skin and a stiffening structure linked on the leading edge side to the spar and to the skin. The stiffening structure being formed from a formed sheet metal having a plurality of bosses distributed according to the length of the leading edge. The bosses extending between the spar and the inner face of the skin.

Abstract: A method for manufacturing a composite part with continuous fiber reinforcement and a polymer matrix from a composite preform. On one of the faces of the composite preform, a demarcated layer of thermoplastic polymer is deposited using an additive manufacturing method.

Abstract: A method for the hot stamping of a composite part with continuous fiber reinforcement in a thermoplastic matrix. A blank including a laminated structure of plies consisting in unidirectional tapes of fibers pre-impregnated with thermoplastic polymer is obtained. The blank is heated in the open to a temperature greater than or equal to the melting temperature of the polymer making up the matrix. The blank is then stamped.

Abstract: An apparatus and method for stamping a thermoplastic matrix composite blank, in view of heating and stamping the blank. The apparatus includes a machined blank and a frame. A plurality of cleats are fixed on the frame, extend towards the interior of the frame. The cleats delimit an internal opening surface of the frame, free from any obstacle. A locator is linked with a cleat and configured to cooperate with a hole machined in the blank. A heat sink is located near the locator and configured to maintain locally the blank temperature under the melting temperature of the polymer constituting the matrix, during the heating and transfer of the blank.

Abstract: A method for making a first ply for laying up a fibrous preform on a tool. An attachment zone is made on the laying up surface of the tool. The zone is integral with the laying up surface of the tool. A polymer is deposited by additive manufacturing on the surface of the tool. The polymer deposit passes on the attachment zone. The first ply is laid up by activating the tackiness of the polymer deposited using additive manufacturing, so as to make the deposited fibers adhere to the material deposited by additive manufacturing.

Abstract: A method for assembling a box structure includes elementary parts assembled along an understructure of stiffeners and skins. The understructure and skins are made of composite material with a polymer matrix. The method includes sizing the box structure for the loads to which it is subjected and for a glued assembly. A map of the loads on the structure is obtained and a first load limit is defined depending on the probability of the structure being damaged. The understructure and the skins are assembled by gluing them. An additional layer is applied that covers the assembled elementary parts to areas of the assembled box structure where the first load limit is reached.

Abstract: A device for fireproofing a section of a structural part made of composite material. The device includes a skin having an outer surface configured to face the flame and an inner surface. The skin is made of composite material that includes fibrous reinforcement in a polymer matrix. The skin includes a fastener to fasten the part to the structure. The device includes a layer of needled mineral felt placed between the inner surface of the skin and a surface of the structural part.

Abstract: A method for forming a thermoplastic composite material with continuous fiber reinforcement by stamping. A flat blank comprising a pre-consolidated stack of plies by automatic fiber placement of fibers referred to as the thermoplastic pre-impregnated fibers is obtained. The flat blank is reheated to a temperature greater than or equal to the melting temperature of the thermoplastic polymer making up the matrix of the thermoplastic pre-impregnated fibers. The reheated flat blank is hot stamped and the part formed between the stamping punch and die is consolidated.

Abstract: A device for welding the bottom flange of a stiffener on the side of a skin. The stiffener and the skin are made of a composite comprising a thermoplastic polymer matrix. The device comprises a punch, an anvil and a press to make a clamping between the punch and the anvil. The punch comprises a part forming a pressure table with a cross-section width less than or equal to the width of the stiffener bottom flange and a heating element with width less than the width of the pressure table. The anvil comprises a cooling component and has a cross-section width smaller than the width of the skin. A method for implementing the device.

Abstract: A laminated composite structural panel with fiber reinforcement comprising a skin with a thickness e1 and a localized reinforcement or patch. The skin is made up of a stack of fibrous plies in a matrix made of a thermoplastic polymer. The localized reinforcement or patch is joined to the surface of the skin and rises to a thickness of e2 in a direction that is locally normal to the skin, which is made up of a stack of fibrous plies in a matrix made of thermoplastic polymer. The surface of the plies that make up the patch is decreasing from the ply of the patch in contact with the skin so that the edges of the patch have a slope p greater than 0.5. The patch and the skin is joined by a weld.