Abstract: A dry fiber form, for use in the preparation of composite parts, is provided with reinforcing threads sewn across the juncture of two non-parallel portions, to prevent failure in the interior of the part due to "out-of-plane" stress developed under applied load, the stress being in a direction other than that of the fibers at said juncture.

Abstract: A process for making a fiber form by preparing structural fabric comprised of a plurality of plies of structural fibers and sewing the fabric with at least one course of resin holding thread. The sewn fiber form is then impregnated with a curable resin and cured to prepare the finished fiber reinforced composite article.

Abstract: A dry fiber form, useful for the preparation of fiber/resin composites, is proposed by stitching a continuous tow of structural yarn to a substrate, according to a predetermined pattern. Numerous layers, similar or different to each other, are prepared, and adhered together. In one embodiment, the fibers are stitched to a removable substrate.

Abstract: A method of molding oriented structural yarn/polymer matrix composite structural articles in which a preform of oriented yarn layers saturated with a resin is placed in a shape-defining mold, which is put in an enclosure, and subjected to heat and pressure to cure the resin, after which a cooling medium may be introduced. To enable the use of lightweight multi-part molds, and a mixture of pressure is distributed evenly, an internal liner is collapsed about the mold prior to curing. The process is extremely productive, and allows for accuracy and reproducibility through the use of real time temperature monitoring and closed loop feedback control.

Abstract: A multiple-end weft-insertion process which is capable of achieving extremely high yarn density which is uniform in plys of structural fabrics is disclosed, making use of conventional machinery and systems. Yarn is transferred from a shuttle to yarn transfer elements spaced a sufficient distance apart to avoid damage to the yarn, and then transferred to yarn holding elements. Each successive pass of the shuttle is adjusted by moving the yarn transfer element parallel to the holding elements, so as to overlap each band deposited by the shuttle. The amount of movement necessary to achieve any desired density is calculated according to established parameters.