Abstract: A belt calender for manufacturing preimpregnated composites includes a first roller, which is rotatable around its longitudinal axis, a first belt running at least partly around the first roller; and a second belt running in between the first roller and the first belt. The first belt and the second belt guide a feed of material between them. The belt calender includes auxiliary rollers which are rotatable around their longitudinal axes, and are arranged substantially parallel to the first roller around at least a part of a circumference thereof. The first and second belt run in between two adjacent ones of the plurality of auxiliary rollers, thereby defining a meandering path for the feed of material. A method for manufacturing preimpregnated composites by using such a belt calender.

Abstract: A mould for manufacturing a turbomachine fan casing made of a composite material with fibrous reinforcement that is densified by a matrix, includes an impregnation mandrel around which a fibrous preform is to be wound and angular counter-mould sectors assembled around the external contour of the impregnation mandrel, which are intended to close the mould. The impregnation mandrel includes a main body with an annular shape, and an annular barrel which is arranged around the main body and around which the fibrous preform is to be wound, the barrel and the angular sectors defining a moulding cavity intended to receive the fibrous preform. The main body and the angular sectors are made of a first material having a first thermal expansion coefficient, the barrel being made of a second material that has a second thermal expansion coefficient, the second thermal expansion coefficient being greater than the first thermal expansion coefficient.

Abstract: A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.

Abstract: A method for forming at least one three-dimensional article through successive fusion of parts of a powder bed on a support structure, the method comprising the steps of: providing at least one model of the three-dimensional article, lowering the support structure a predetermined distance and rotating the support structure a predetermined angle in a first direction before applying a first powder layer covering the lowered and rotated support structure, rotating the support structure the predetermined angle in a second direction opposite to the first direction before directing the at least one first energy beam from the at least one first energy beam source at selected locations of the first powder layer, the at least one first energy beam source causing the first powder layer on the stationary support structure which is stationary to fuse in the selected locations according to the model to form first portions of the three-dimensional article.

Abstract: A manufacturing system (1) for manufacturing shaped laminates including: forming tools (2.1, 2.2) extending along a longitudinal direction X, located parallel to one another and configured to receive a laminate (4) between the forming tools; a shaping tool (3) extending along the longitudinal direction X and along a transversal direction Z, and configured to receive the laminate (4) on an external surface of the shaping tool, wherein the forming tools (2.1, 2.2) or the shaping tool (3) are movable in the longitudinal direction X and in the transversal direction Z, relative to the at least one of the shaping tool (3) and the two forming tools (2.1, 2.2).

Abstract: An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Abstract: A multi-cavity mould (1) for a thermoforming machine used in the process of high-volume, continuous thermoforming of a plurality of thin-gauge plastic products (2) from a preheated thin-gauge thermoplastic sheet (3) comprising an upper tool (11) and a lower tool (12) arranged in a cooperating manner; the lower tool (12) comprising a plurality of cavities (8) in which cavity moulds (8) are placed and a plurality of base plates (91) from which a plurality of supporting blocks (92) extend perpendicularly over a predetermined total height (a), situated between adjacent cavities (8), each of said supporting block (92) has a stepped profile comprising three substantially rectangular shaped zones (92a, 92b, 92c) and a fourth substantially isosceles trapezoid shaped zone (92d) in a vertical cross section, having a common symmetry axis.

Abstract: A method of forming a composite vehicle components (e.g. walls, floor, roof) having interleaved foam core members and pre-pultruded reinforcing pillars by pultruding the cores and pillars into a vehicle component (e.g. bus sidewall formed as integral component front to rear) and cutting apertures therein for insertion of vehicle accessories (e.g. windows). Also, vehicle components can be formed having interlocking profiled edges where a first component is inserted into a second component, and rotated to bring the two components into locking engagement. A plurality of components can be formed with the same geometry, and oriented 180 degrees offset from each other to bring their profiled edges adjacent to each other.

Abstract: A serving tray comprised of at least one synthetic material and an insert which provides a non-slip top surface of the serving tray. The textured relief is preferably made of thermoplastic polyurethane (TPU) which allows a glass or other item to be placed on the serving tray without the item sliding or slipping while the tray is in motion. As the tray is being fabricated, the TPU is mechanically bonded with the top surface of the tray while a textured relief is simultaneously defined into the top surface. The textured relief provides adequate frictional force to an item being placed on the tray so as to substantially prevent its lateral movement. The tray also includes an inner support structure disposed on its inner surface. The inner support structure provides an upward facing edge which allows a plurality of trays to be easily and efficiently stacked or nested on one another.

Abstract: One embodiment of a method according to the present disclosure may use an outer member having the required structural rigidity and/or structural integrity such that no thermoforming tool, no support base, no fixture, no cover, no caul plate, no bag, and/or no table are required to make the part as desired. Substrate lay-up may be placed around all or a portion the outer member. A cover may be positioned over the outer member and the pressure within an interior portion of the outer member and cover may be reduced to less than ambient pressure and resin may be introduced to interact with the substrate lay-up and allowed to cure.

Abstract: A mold assembly for producing a part includes a first section, a second section movably coupled to the first section, and a cavity defined by the first section and the second section, the cavity being shaped to receive a part while the first section and the second section are movably coupled to each other. The mold assembly includes a joint formed by adjacent surfaces of the first section and the second section and a seal extending along the joint.

Abstract: A main object of the present invention is to provide beneficial improvements relating to a method for producing a fiber reinforced plastic product, the method including curing while pressurizing a prepreg preform by using a core having a fusible part as means for pressurizing.

Abstract: A three-dimensionally laminated object modeling apparatus includes a cylinder configured to store a molten resin, a discharging nozzle that is communicated with the cylinder, and a piston configured to discharge the molten resin from the discharging nozzle by moving in a direction of approaching the discharging nozzle and by pressurizing the molten resin in the cylinder, and models a three-dimensionally modeled object by laminating a resin bead that is the molten resin discharged from the discharging nozzle on a table. It includes a drive device configured to relatively move the discharging nozzle with respect to the table and at least one processor configured to acquire a movement speed of the discharging nozzle and control movement of the piston based on the movement speed of the discharging nozzle.

Abstract: A method for creating a fan cowl with a hollow hat stiffener includes pressing a resin film between a non-crimp fabric (NCF) and a release poly-film to create a resin-fabric sheet. The method further includes cutting the resin-fabric sheet to a pre-determined shape to create at least one of a first resin-fabric preform, a second resin-fabric preform, and a third resin-fabric preform, draping at least the first resin-fabric preform over a tool to create an outer layer of the fan cowl, setting a mandrel over the outer layer, and draping the second resin-fabric preform over at least a portion of the mandrel and at least a portion of the first resin-fabric preform to form the hollow hat stiffener having a geometry similar to a shape of the mandrel.

Abstract: According to some aspects, techniques are described for generating support structures that may be easily removed after fabrication yet provide sufficient structural support during fabrication. In some cases, the techniques may include tuning an extent to which pillars of a support structure are interconnected to one another in regions proximate to the part. In some cases, the techniques may include fabricating very small contact structures, referred to herein as “hair” supports, in regions of a support structure where it connects with the part. In some cases, the techniques may include generating support structures that comprise obliquely-angled tips, which allow forces during fabrication to be applied in a preferred direction even when the support structure does not make a connection to the part in the preferred direction.

Abstract: A method for producing injection-molded parts by a two-component injection-molding technique in which a first material component is injected into a mold cavity and is displaced into peripheral regions of the mold cavity by injecting a second material component. The first material component is injected into a partial region of the mold cavity at a first gating point and the second material component is injected into the mold cavity at a second gating point and, as a result, the first material component is acted upon by the second material component and displaced in the direction of the regions of the mold to be filled with the first material component. The first material component is thereby displaced into regions of the mold at the wall, and the second material component is introduced in those regions of the mold as a core material and completely into other regions of the mold.

Abstract: A method of manufacturing a structural member includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, applying a binder having a viscosity lower than 25 centipoise to at least one of the preheated fibers, providing a die shaped to receive the preheated fibers, wherein the die moves together with the preheated fibers along at least a portion of the assembly line, maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature, and compressing the plurality of fibers within the die while maintaining a temperature.

Abstract: A method for calibrating a 3D printer includes the steps of providing information obtained in a factory calibration indicating a center of an inner diameter of a tip orifice in a metal extrusion nozzle and a center of a tip surface for the nozzle and inductively sensing the nozzle with an eddy current sensor when secured to a print head on a gantry or robotic arm of the 3D printer to identify a sensed location of the center of the tip surface of the nozzle. The method includes determining a location of the center of the inner diameter of the tip orifice on the nozzle on the print head and utilizing the provided information to locate the center of the inner diameter of the tip orifice.

Abstract: A process for shaping, by compaction, a fibrous structure obtained by three-dimensional or multilayer weaving between a plurality of layers of warp yarns and a plurality of layers of weft yarns. The yarns of each plurality of layers of warp yarns and layers of weft yarns are coated with a sizing composition. The shaping includes a pre-compaction stage followed by a stage of final compaction of the fibrous structure. During pre-compaction and final compaction, the fibrous structure is at a temperature greater than or equal to the softening temperature of the sizing composition. The process further includes the cooling of the fibrous preform obtained after final compaction of the fibrous structure.

Abstract: A method of printing a 3D part with an additive manufacturing system includes printing a first portion of the part and pre-heating the first portion of the part along an upcoming tool path to a temperature at or above a material-specific bonding temperature and below a degradation temperature of the material. Material is extruding material onto the first portion along the pre-heated tool path while the temperature along the part surface remains at or above a material-specific bonding temperature and below the degradation temperature of the material thereby forming a newly extruded road. The method includes cooling the newly extruded road along the pre-heated tool path to remove heat imparted by the preheating step such that a thermally stable temperature is reached, wherein the preheating, extruding and cooling is performed in less than ten seconds.