Abstract: A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

Abstract: An aged granular material and a method of manufacturing an object from the granular material include introducing a granular material into a molding process so as to form the object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

Abstract: In an embodiment of the disclosure, there is provided a method of prototyping a thermoplastic composite part. The method comprises fabricating one or more discardable freeform tooling elements via a rapid manufacturing process. The method further comprises forming thermoplastic composite materials into a thermoplastic composite prototype part using the one or more discardable freeform tooling elements. The method further comprises separating the thermoplastic composite prototype part from the one or more discardable freeform tooling elements.

Abstract: A method of fabricating a vacuum barrier system includes fabricating a soluble forming mandrel, laying up composite material over the soluble forming mandrel, and applying a forming mandrel vacuum bag over the composite material and curing the composite tooling material to form a cured composite bag carrier. The method also includes de-bagging and trimming the cured composite bag carrier.

Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

Abstract: Core structures (120) for composite panels (75) of an aircraft (10), composite panels (75) and aircraft (10) including the core structures (120), and methods (200) of manufacturing the composite panels (75) are disclosed herein. The core structures (120) include a first side (140), a second side (150), and a connecting region (160) that interconnects an upper portion (142) of the first side (140) with an upper portion (152) of the second side (150). The first side (140), the second side (150), and the connecting region (160) at least partially define an antenna housing (62), which defines a housing volume (64) configured to contain an aircraft antenna (60) of the aircraft (10), and an electromagnetic wave transmission region (66) configured to permit electromagnetic waves to pass therethrough.

Abstract: Core structures (120) for composite panels (75) of an aircraft (10), composite panels (75) and aircraft (10) including the core structures (120), and methods (200) of manufacturing the composite panels (75) are disclosed herein. The core structures (120) include a first side (140), a second side (150), and a connecting region (160) that interconnects an upper portion (142) of the first side (140) with an upper portion (152) of the second side (150). The first side (140), the second side (150), and the connecting region (160) at least partially define an antenna housing (62), which defines a housing volume (64) configured to contain an aircraft antenna (60) of the aircraft (10), and an electromagnetic wave transmission region (66) configured to permit electromagnetic waves to pass therethrough.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.

Abstract: A method of forming a monolithic aircraft part includes additively forming a first cavity, defined by a first wall of the part, additively forming a second cavity, defined by a second wall of the part, so that the first cavity and the second cavity are not in communication with each other and share a common wall portion so that the second cavity is partially contained within the first cavity. Additively forming the first cavity includes forming a first aperture, extending through the first wall, forming a second aperture, extending through the first wall, and forming a first inner surface of the first wall, defining a first shape, wherein a first object, permanently having the first shape, would not be able to be mechanically extracted from the first cavity via the first aperture or the second aperture.

Abstract: An aged granular material and a method of manufacturing an object from the granular material include introducing a granular material into a molding process so as to form the object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

Abstract: A textile product and a method of manufacturing a composite object therefrom includes interacting a granular material with a textile material, with the textile material impregnated with the elements of the granular material forming a textile product, and introducing the textile product into a molding process so as to form the composite object therefrom. The granular material includes elements including a matrix material having a plurality of reinforcing fibers received therein, the elements of the granular material having a melt viscosity of between about 5 and about 15 grams per 10 minutes and a particle size distribution with a range in particle size of between about 50 and about 595 micrometers.

Abstract: An aircraft wing tip device may include a unitized, monolithic leading edge torque box that may be formed of polymer matrix fiber-reinforced material. The leading edge torque box may include a skin that may define a continuous, uninterrupted outer mold line surface extending aftwardly from a winglet leading edge by a distance of at least approximately 60 percent of a local chord length. The leading edge torque box may further include at least one internal component extending between opposing inner surfaces of the skin and being integrally formed therewith.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

Abstract: One example of the present disclosure relates to a monolithic part including an exterior wall and a first cavity. The first cavity includes a first aperture in communication with the exterior wall and a first inner surface defining a first shape. The first Shape prevents extraction from the first cavity, via the first aperture, of a first virtual object having the first shape.

Abstract: A vacuum barrier system for curing a composite part may include a bag carrier and a compliant, relatively thin film bladder formed over the bag carrier to function as a vacuum barrier. The bag carrier may be configured complementary to the composite part. The bladder may seal the bag carrier therewithin.

Abstract: A method of fabricating a vacuum barrier system includes fabricating a soluble forming mandrel, laying up composite material over the soluble forming mandrel, and applying a forming mandrel vacuum bag over the composite material and curing the composite tooling material to form a cured composite bag carrier. The method also includes de-bagging and trimming the cured composite bag carrier.

Abstract: One example of the present disclosure relates to a monolithic part including an exterior wall and a first cavity. The first cavity includes a first aperture in communication with the exterior wall and a first inner surface defining a first shape. The first shape prevents extraction from the first cavity, via the first aperture, of a first virtual object having the first shape.