Abstract: Various embodiments provide an apparatus, method, and/or system by which fiber, e.g., in the form of tow or tow, is used to create a shaped ply by facilitating drawing fiber from a supply along a fiber axis between two sets of pins; moving the pins across the fiber axis to form a fiber web in the desired ply shape; fixing the fiber web to form the shaped ply; and releasing the shaped ply. By enabling formation of shaped plies (including plies with doubly curved surfaces and simultaneous sequences of strategically shaped plies) directly from a single piece of fiber tow, various embodiments discussed herein enable substantial reductions in labor and materials costs that are conventionally associated with construction of composite preforms and accompanying composite products.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N-K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: A process to create composite preforms and parts by stacking layers of two-dimensional fiber material (e.g., fiber cloth, fiber reinforced fabric, etc.) having pin-receiving holes and/or gaps disposed between the fibers of the fiber material is described. The stack is pinned together using a subset of pins, such as fiber reinforcing pins, inserted into a subset of the pin receiving holes and/or gaps, leaving at least some of the pin receiving holes and/or gaps available for pinning other layers, as layers of fiber material are added to the stack. As additional layers are added to the stack, different subsets of pins connect the additional layers to the stack, thereby building up the stack. Each layer of fiber material may have a different shape than the other layers and any arbitrary topology, potentially including non-convex and/or disjoint shapes. Furthermore, implementations may produce composite preforms having an arbitrary number of interconnected layers.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N?K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N?K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: Methods creating composite preforms with a three-dimensional weaving pattern include stacking material layers and then connecting them with interlayer reinforcements. First and second layers are aligned and separated by a first layer spacing. First interlayer reinforcements are then inserted through at least the first and the second layers. At least a third layer is aligned with at least the first and second layers. Second interlayer reinforcements are inserted through at least the second and third layers, using the first layer spacing between the first and second layers to manipulated the second interlayer reinforcements during insertion. Following the insertion of at least the second interlayer reinforcement, this layer spacing is closed to bring the first and second layers into contact. Further layers and interlayer reinforcements may be added, using additional layer spacings to manipulate additional interlayer reinforcements to form complex three-dimensionally woven composite preforms.

Abstract: Systems and methods fabricate composite preforms in a flat or unfolded format. Following fabrication, the preform is folded and placed in or around a mold for curing. To facilitate folding and produce strong parts, the preform is fabricated with integrated, 3D woven joints at preform edges. These joints connect the folded preform portions to other parts of the preform, such as other unfolded or folded preform portions or internal features. Integrated joints may be flexible to facilitate assembly prior to curing. The unfolded preform design may be generated from a preform model by splitting the preform model at an initial joint location, unfolding the preform model into an unfolded preform, creating joint connectors in the unfolded preform at the initial joint location, determining a fiber layup of the unfolded preform, and generating fabrication data.