Abstract: Lightweight and strong components having any desired shape, form, or geometry may be manufactured using thermally expanding mandrels by the processes described herein. A thermally expanding mandrel may be formed from an expanding material composition including thermally expanding particles, e.g., micronized rubber particles, and water-soluble binder material, e.g., gypsum plaster. Component material may be applied to the mandrel, and the mandrel may be inserted into a molding tool. Upon application of heat to the mandrel, the mandrel may expand, and compress and cure the component material into a component within the molding tool. Following formation of the component, the mandrel may be washed out of the component, e.g., using pressurized water, and the expanding material composition may be recycled and/or reused.

Abstract: Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Abstract: Expandable components for aerial vehicles may include an outer structure formed of carbon fiber, an adhesive bladder disposed within the outer structure, and expanding foam materials inserted into the adhesive bladder. The expandable components may be configured to transform from a compressed configuration to an expanded configuration upon application of heat and/or pressure. For example, in the compressed configuration, the outer structure, adhesive bladder, and expanding foam materials may be folded, rolled, or compressed for storage or transport. In the expanded configuration, the expanding foam materials may expand and cure within the adhesive bladder, the adhesive bladder may expand, bond, and cure inside the outer structure, and the outer structure may expand and cure to a desired shape or size.

Abstract: Manufacturing systems for expandable components may include a controller, a heat and/or pressure source, and a transfer line. For example, the expandable components may be configured to transform from a compressed configuration to an expanded configuration upon application of heat and/or pressure. In addition, the controller may activate the heat and/or pressure source to release heat and/or gases that are directed to the expandable components via the transfer line. Further, the manufacturing system may also include an igniter, a manifold, and a valve to further control the release of heat and/or gases. Moreover, at least a portion of the heat and/or gases may be recaptured in a closed chamber and redirected to additional expandable components in other closed chambers. Furthermore, various post-processing may be performed on the components in their expanded configurations.

Abstract: Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Abstract: Methods for detecting irregularities in a composite structure can include obtaining temperature data from a surface of the composite structure while the composite structure undergoes a thermal change. An irregularity in the composite structure is detected based on the temperature data.

Abstract: Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Abstract: Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Abstract: Lightweight and strong components having any desired shape, form, or geometry may be manufactured using thermally expanding mandrels by the processes described herein. A thermally expanding mandrel may be formed from an expanding material composition including thermally expanding particles, e.g., micronized rubber particles, and water-soluble binder material, e.g., gypsum plaster. Component material may be applied to the mandrel, and the mandrel may be inserted into a molding tool. Upon application of heat to the mandrel, the mandrel may expand, and compress and cure the component material into a component within the molding tool. Following formation of the component, the mandrel may be washed out of the component, e.g., using pressurized water, and the expanding material composition may be recycled and/or reused.

Abstract: Methods for detecting irregularities in a composite structure can include obtaining temperature data from a surface of the composite structure while the composite structure undergoes a thermal change. An irregularity in the composite structure is detected based on the temperature data.

Abstract: Methods for detecting irregularities in a composite vehicle can include cooling the composite vehicle to a substantially uniform first temperature, heating a surface of the composite vehicle to a second temperature that is higher than the first temperature, and obtaining temperature data from the composite vehicle after the surface has been heated. An irregularity in the composite vehicle is detected based on the temperature data.

Abstract: Methods for detecting irregularities in a composite structure can include obtaining temperature data from a surface of the composite structure while the composite structure undergoes a thermal change. An irregularity in the composite structure is detected based on the temperature data.

Abstract: Methods for detecting irregularities in a composite vehicle can include cooling the composite vehicle to a substantially uniform first temperature, heating a surface of the composite vehicle to a second temperature that is higher than the first temperature, and obtaining temperature data from the composite vehicle after the surface has been heated. An irregularity in the composite vehicle is detected based on the temperature data.

Abstract: Methods for detecting irregularities in a composite structure can include obtaining temperature data from a surface of the composite structure while the composite structure undergoes a thermal change. An irregularity in the composite structure is detected based on the temperature data.