Abstract: Methods and apparatus for manufacturing a thermoplastic structure include laying a first plurality of braided plies on a mandrel, and laying one or more unidirectional plies on the plurality of braided plies. A second plurality of braided plies is laid on the one or more unidirectional plies. The layup thereby forms a thermoplastic structure having combined braided and unidirectional plies.

Abstract: A braiding apparatus for forming braided tubing comprises a braiding wheel and a plurality of bobbins. The plurality of bobbins are configured to move circumferentially around the braiding wheel. Each bobbin includes a spool, a first pulley assembly, and a second pulley assembly. The spool is configured to hold a tow formed from a braiding material. The first pulley assembly is coupled to the spool at a first distance from the spool. The first pulley assembly is configured to facilitate passing the tow over a pulley of the first pulley assembly. The second pulley assembly is coupled to the spool at a second distance that is less than the first distance. The second pulley assembly is configured to facilitate receiving the tow from the first pulley assembly and passing the tow over a pulley of the second pulley assembly and towards a section of the braiding apparatus at which a plurality of tows come together to form the braided tubing.

Abstract: At least one braided composite layer configured to form a first ply may be provided. A plurality of slit tapes may be arranged and aligned such that each slit tape is adjacent to one another and non-overlapping, to form a second ply. A hybrid composite laminate may be formed by stacking a plurality of plies that includes at least one first ply and at least one second ply. Each slit tape may be a steered unidirectional composite slit tape that is aligned along an axis, contour line, or curve of the hybrid composite laminate, a mold/tooling used to shape the laminate, or the resulting composite part. Hybrid composite laminates may be formed by stacking at least one first ply formed of a braided composite layer and at least one second ply formed from a plurality of slit tapes. Composite parts may be formed by consolidating such hybrid composite laminates.

Abstract: A thermoplastic composite structure is produced by consolidating and forming a composite preform to a desired shape. The preform comprises plies of a high melt temperature thermoplastic prepreg that are tacked together by a low melt temperature thermoplastic adhering the plies together in fixed registration.

Abstract: Systems and methods are provided for consolidating a preform of braided fiber. One embodiment is a method that includes acquiring a braided preform comprising fibers of unidirectional material that have been woven into a shape having a closed cross-section, disposing the braided preform within a mandrel, disposing an inflatable bladder within the closed cross-section of the braided preform, and iteratively applying pressure to the braided preform via the bladder to consolidate the braided preform against the mandrel.

Abstract: A tool for forming a part includes a first tool portion including a first tool surface. The tool further includes a second tool portion comprising a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the part. The tool further includes a bladder subassembly disposed in the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within tool chamber, wherein each inner bladder of the plurality of inner bladders includes an inner bladder chamber that is independently inflatable to selectively apply pressure to the part. The bladder subassembly further includes a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the part.

Abstract: A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Abstract: Systems and methods are provided for fabricating a laminate. One method includes laying up a first set of layers comprising tows of unidirectional thermoplastic fiber-reinforced material for the laminate, and laying up a second set of layers comprising tows of braided thermoplastic fiber-reinforced material for the laminate.

Abstract: A braiding apparatus for forming braided tubing comprises a braiding wheel and a plurality of bobbins. The plurality of bobbins are configured to move circumferentially around the braiding wheel. Each bobbin includes a spool, a first pulley assembly, and a second pulley assembly. The spool is configured to hold a tow formed from a braiding material. The first pulley assembly is coupled to the spool at a first distance from the spool. The first pulley assembly is configured to facilitate passing the tow over a pulley of the first pulley assembly. The second pulley assembly is coupled to the spool at a second distance that is less than the first distance. The second pulley assembly is configured to facilitate receiving the tow from the first pulley assembly and passing the tow over a pulley of the second pulley assembly and towards a section of the braiding apparatus at which a plurality of tows come together to form the braided tubing.

Abstract: Systems and methods are provided for fabricating a laminate. One method includes laying up a first set of layers comprising tows of unidirectional thermoplastic fiber-reinforced material for the laminate, and laying up a second set of layers comprising tows of braided thermoplastic fiber-reinforced material for the laminate.

Abstract: A tie rod that includes a central section, a first tapered section, and a second tapered section. A thermoplastic tube extends the length of the tie rod. The first tapered section includes a first insert positioned within the thermoplastic tube. The second tapered section includes a second insert positioned within the thermoplastic tube. A channel extends through the tie rod along the central section, the first tapered section, and the second tapered section.

Abstract: A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Abstract: Systems and methods are provided for fabricating a hybrid composite part. A method includes braiding a first set of fibers to form a weave having a closed cross-sectional shape, braiding a second set of fibers into the weave that are chemically distinct from the first set of fibers, impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part.

Abstract: Composite laminate structures are produced using partially cured parts. Partial curing of the parts is achieved by applying a catalyst to regions of the parts that are to be fully cured. These regions cure at a lower-than-normal temperature while remaining regions of the part remain uncured, allowing them to be co-bonded or co-cured to other structures.

Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.

Abstract: A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Abstract: Systems and methods are provided for fabricating a hybrid composite part. A method includes braiding a first set of fibers to form a weave having a closed cross-sectional shape, braiding a second set of fibers into the weave that are chemically distinct from the first set of fibers, impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part.

Abstract: A tool for forming a part includes a first tool portion including a first tool surface. The tool further includes a second tool portion comprising a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the part. The tool further includes a bladder subassembly disposed in the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within tool chamber, wherein each inner bladder of the plurality of inner bladders includes an inner bladder chamber that is independently inflatable to selectively apply pressure to the part. The bladder subassembly further includes a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the part.

Abstract: A tie rod that includes a central section, a first tapered section, and a second tapered section. A thermoplastic tube extends the length of the tie rod. The first tapered section includes a first insert positioned within the thermoplastic tube. The second tapered section includes a second insert positioned within the thermoplastic tube. A channel extends through the tie rod along the central section, the first tapered section, and the second tapered section.

Abstract: This disclosure is directed to a thermoplastic composite material forming method and tooling used to perform the method. More specifically, this disclosure is directed to a method of fabricating large, complex thermoplastic composite part shapes with a consolidation tool having a conformable tooling bladder that heat thermoplastic material in the tool and provide thermoplastic material consolidation pressure in directions in the tool to form a part shape of thermoplastic composite material. A novel tooling concept is used to fabricate large, complex thermoplastic composite part shapes which are not easily producible using traditional methods.