Abstract: A method of manufacturing a composite panel for an air vehicle having a predetermined size and shape. The method includes forming a frame including an outer mold line surface and at least one edge extending from the outer mold line surface. The outer mold line surface includes an OML inner surface. The edge includes an edge inner surface and an edge outer surface opposite the edge inner surface. The OML inner surface and the edge inner surface define a cavity. The method also includes positioning a plurality of uncured plies within the cavity. The OML inner surface and the edge inner surface support the uncured plies during a curing process. The method further includes curing the uncured plies using the curing process. A post-cure size and shape of the cured plies and the frame corresponds to the predetermined size and shape without trimming any of the cured plies.

Abstract: A method of manufacturing a composite panel for an air vehicle having a predetermined size and shape. The method includes forming a frame including an outer mold line surface and at least one edge extending from the outer mold line surface. The outer mold line surface includes an OML inner surface. The edge includes an edge inner surface and an edge outer surface opposite the edge inner surface. The OML inner surface and the edge inner surface define a cavity. The method also includes positioning a plurality of uncured plies within the cavity. The OML inner surface and the edge inner surface support the uncured plies during a curing process. The method further includes curing the uncured plies using the curing process. A post-cure size and shape of the cured plies and the frame corresponds to the predetermined size and shape without trimming any of the cured plies.

Abstract: A composite truss structure may have a first facesheet, a second facesheet, and a plurality of truss elements joined with the first facesheet and the second facesheet at nodes to form a one-piece structure. The composite truss structure may be formed by a method comprising preparing a dry fabric mold by: 1) placing a first dry fabric layer on a tool, 2) placing a first layer of fabric-loaded mandrels on the first dry fabric layer, 3) placing a second layer of the fabric-loaded mandrels on the first layer of fabric-loaded mandrels, and 4) placing a second dry fabric layer over the fabric-loaded mandrels. The method may further comprise infusing the dry fabric mold with a resin, and curing the resin to provide the nonflexible composite truss structure.

Abstract: A system for manufacturing a composite structure includes a tool with a surface for supporting component elements of the composite structure. The surface is divided into a multi-dimensional array of thermal zones for in-process control of the temperature of a component element (e.g. resin) of the composite structure. The sensors sense a characteristic of the component element and provide sensor data, which is applied to a machine-learning algorithm configured to generate control data to achieve a defined quality goal. A controller then independently controls the thermal zones to locally heat, cool or maintain the temperature of the component element according to the control data to advance the component element or composite structure to the defined quality goal. This may be performed over a plurality of instances during which the machine-learning algorithm learns to increase advancement of the component element or composite structure to the defined quality goal.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts. The method allows for a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish. The component may be placed in direct contact with a tool, and the caul sheet may be placed in direct contact with the component thereby eliminating the necessity for consumables between these items.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: A system for manufacturing a composite structure includes a tool with a surface for supporting component elements of the composite structure. The surface is divided into a multi-dimensional array of thermal zones for in-process control of the temperature of a component element (e.g. resin) of the composite structure. The sensors sense a characteristic of the component element and provide sensor data, which is applied to a machine-learning algorithm configured to generate control data to achieve a defined quality goal. A controller then independently controls the thermal zones to locally heat, cool or maintain the temperature of the component element according to the control data to advance the component element or composite structure to the defined quality goal. This may be performed over a plurality of instances during which the machine-learning algorithm learns to increase advancement of the component element or composite structure to the defined quality goal.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Abstract: A composite truss structure may have a first facesheet, a second facesheet, and a plurality of truss elements joined with the first facesheet and the second facesheet at nodes to form a one-piece structure. The composite truss structure may be formed by a method comprising preparing a dry fabric mold by: 1) placing a first dry fabric layer on a tool, 2) placing a first layer of fabric-loaded mandrels on the first dry fabric layer, 3) placing a second layer of the fabric-loaded mandrels on the first layer of fabric-loaded mandrels, and 4) placing a second dry fabric layer over the fabric-loaded mandrels. The method may further comprise infusing the dry fabric mold with a resin, and curing the resin to provide the nonflexible composite truss structure.

Abstract: A controller is disclosed that controls an entertainment system which includes a video display unit that is separate from the controller. The controller includes a network interface, a display device, and a processing device. The network interface communicates with the video display unit via at least one data network. The processing device communicates a first command over the at least one data network to control a display of first content on the video display unit, and controls a display of second content on the display device of the controller. The second content is displayed concurrently with the first content. Related entertainment systems are disclosed.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure. The stiffener and runout may comprise a crown, side walls, and base cap. The transition in the runout may include a width of the crown increasing, a height of the side walls decreasing, and the base cap splaying outwardly.

Abstract: A composite structure is made by placing a stiffener preform and a composite structure reinforcement on a tool. The preform and the reinforcement are vacuum bagged processed and co-infused with a thermoset resin to form a stiffened, unitized structure.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts. The method allows for a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish. The component may be placed in direct contact with a tool, and the caul sheet may be placed in direct contact with the component thereby eliminating the necessity for consumables between these items.

Abstract: A controller is disclosed that controls an entertainment system which includes a video display unit that is separate from the controller. The controller includes a network interface, a display device, and a processing device. The network interface communicates with the video display unit via at least one data network. The processing device communicates a first command over the at least one data network to control a display of first content on the video display unit, and controls a display of second content on the display device of the controller. The second content is displayed concurrently with the first content. Related entertainment systems are disclosed.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Abstract: A composite structure is made by placing a stiffener preform and a composite structure reinforcement on a tool. The preform and the reinforcement are vacuum bagged processed and co-infused with a thermoset resin to form a stiffened, unitized structure.