Abstract: Embodiments of a method to fabricate complex structures include making a pre-cured laminate template. The laminate template is first cured to the required shape, then surface prepared for joining to additional composite lamina. The laminate templates are used to position composite lamina in contact with one another. The composite lamina are then co-cured together to form one monolithic composite structure lacking bond lines or bonded joints. The laminate template supports additional composite lamina for formation of complex structures and replaces template tools from conventional methods.

Abstract: A method for making a fuselage section comprises the steps of assembling a support system. The support system comprises fiber reinforced composite material and includes at least three frames and six stringers. The support system is partially cured such that the support system attains about eighty percent of its fully cured strength. A skin comprising fiber reinforced composite material is globally positioned such that an inner surface of the skin corresponds to an outer surface of the support system. The skin and the support system are fully cured together. The support system is assembled on a skeleton assembly tool having a bonding surface corresponding to an inner surface of the skin.

Abstract: A fiber reinforced composite structure includes multiple plies of pre-impregnated fiber reinforced material. Consecutive plies are layered such that the fibers of one ply are at 90 degrees relative to the fibers of a proximate ply, and such that the fibers of each ply are oriented at positive or negative 45 degrees with respect to a reference plane of the fiber reinforced composite structure. In a method for fabricating a fiber reinforced composite structure, pre-impregnated fiber reinforced composite plies are layered into a tool layup. Each ply is cut on the bias at either plus 45 degrees or minus 45 degrees. The bias angles of the layered plies alternate one relative to the next. The layered plies are cured after layering.

Abstract: An internally heated and pressurized system for fabricating a composite laminate structure and method for use thereof is disclosed. One of a plurality of thin, thermally conductive bond tools, prepreg fiber reinforced composite layers, and a pressure applying membrane are nested within a heated base, and then covered by a pressure sealed cover. The system is pressurized through the pressure sealed cover. The pressure causes the pressure applying membrane to force the prepreg fiber reinforced composite layers onto the upper surface of the bond tool. The heated base transfers heat to the composite layers via the bond tool, which heats and cures the composite layers together and to a shape determined by the upper surface of the bond tool. Each bond tool is formed with a generic lower surface for nesting within the heated base and an upper surface for forming composite layers into the shape of a specific part.

Abstract: A method for making a fuselage section comprises the steps of assembling a support system. The support system comprises fiber reinforced composite material and includes at least three frames and six stringers. The support system is partially cured via a fast cure process such that the support system attains about eighty percent of its fully cured strength. A skin comprising uncured fiber reinforced composite material is globally positioned such that an inner surface of the skin corresponds to an outer surface of the support system. The skin and the support system are fully cured together. The support system is assembled on a bonding tool having a bonding surface corresponding to an inner surface of the skin.