Abstract: Methods for fabricating fiber-composite truss structures comprise a) individually molding multiple unit cells of a given size, and subsequently fusing them together in a repeating pattern, b) cross members are consolidated with longerons while maintaining continuity of fiber in the longerons, and c) compression-molded truss components are unioned to continuous fiber beams by means of mechanically interlocking joints.

Abstract: A compression-molding apparatus includes a sleeve plunger and a core pin. The sleeve plunger is movable through a plunger cavity that, in some embodiments, extends through the male portion of the molding apparatus. The sleeve plunger has a bore, and is received by and movable along the core pin, which typically extends upward into the plunger cavity from the female portion of the molding apparatus. In addition to any other functionality, the core pin forms a hole in a molded part. In operation, the fiber-bundle-based-preform feed constituents are placed in the plunger cavity. If any of the preforms are ring-shaped preforms, they are received by the core pin.

Abstract: A multi-material molding apparatus and method includes a single mold having, within a mold cavity, one or more movable partitions that segregate at least first and second molding materials. The first molding material is processed to form a first molded portion of the multi-material part. The second molding material is then flowed, through the movable partition, into contact with the first molded portion. That second molding material is then solidified to form a second molded portion of the multi-material part.

Abstract: An impact-absorbing article includes two outer panels that sandwich a fiber-composite post-and-sheet layer. The post-and-sheet layer includes a plurality of fiber-composite “posts” that extend orthogonally with respect to a base.

Abstract: In an injection/compression-molding process, an assemblage of fiber-bundle-based preforms are placed in a mold cavity of a mold tool. The mold is then fully closed, but not pressurized. An injection charge, which includes resin and optionally short fibers, is placed in a plunger cavity that is in fluidic communication with the mold cavity. The injection charge is liquefied and injected into the mold cavity, pressurizing it to a pressure suitable for compression molding. If not previously liquefied, the resin in fiber-bundle-based preform is liquefied and, under the applied pressure, the resins and fibers are consolidated and then cooled to form a part.

Abstract: A wave spring comprises fiber in a thermoplastic resin matrix, and includes one or more annular wave-springs elements, or one or more curvilinear wave-spring elements. The annular wave-spring elements, which are arrayed in a stack, are not coupled to one another. A wave spring comprising annular wave-spring elements includes an alignment feature for establishing and maintaining the alignment of the wave spring elements. In a wave spring including curvilinear wave-spring elements, a first end of each curvilinear wave-spring element is attached to a first member and a second end of each curvilinear wave-spring element is attached to a second member, the plurality of curvilinear wave-spring elements being disposed between the two members. The plurality of curvilinear wave-spring elements in the array are positioned side by side, the array extending laterally along a length of the first member and second member, and providing a low-profile wave spring.

Abstract: An impact-absorbing article includes two outer panels that sandwich a fiber-composite post-and-sheet layer. The post-and-sheet layer includes a plurality of fiber-composite “posts” that extend orthogonally with respect to a base.

Abstract: A method for designing fiber-composite parts in which part performance and manufacturing efficiency can be traded-off against one another to provide an “optimized” design for a desired use case. In some embodiments, the method involves generating an idealized fiber map, wherein the orientation of fibers throughout the prospective part align with the anticipated load conditions throughout the part, and then modifying the idealized fiber map by various fabrication constraints to generate a process-compensated preform map.

Abstract: A system and methods are disclosed for producing components via additive manufacturing. In one embodiment, a three-dimensional geometry is sliced using a slicing plane to obtain a first two-dimensional geometry. A first polyline is generated based on a first skeleton of the first two-dimensional geometry, and a first slender body is generated based on the first polyline. The first slender body is subtracted from the first two-dimensional geometry to obtain a second two-dimensional geometry. A second polyline is generated based on a second skeleton of the second two-dimensional geometry. A first bundle of fibers is produced based on a segmentation of the first polyline and a second bundle of fibers is produced based on a segmentation of the second polyline. A component is produced from the first and second bundles of fibers using an additive manufacturing process.

Abstract: A molding apparatus for injection molding or compression molding includes an “A” portion of a mold, a “B” portion of the mold, and at least one core plunger/ejector. The core plunger/ejector provides dual functionality, wherein it participates in molding operations by consolidating a feed material in the mold cavity, and also is responsible for separating the part from various mold surfaces and ejecting it from the mold.

Abstract: A multi-part compression mold for forming a complex part having a desired fiber alignment, and methods therefor, are disclosed. The multi-part mold comprises at least three sections. Specific arrangements of fiber-bundle-based preforms are introduced to more than one of the mold sections of the multi-part mold, and subjected to compression molding. The arrangements of preforms, in conjunction with the multi-part mold, result in a complex part having fibers that substantially align with anticipated principle stress vectors that arise in the complex part, when in use.

Abstract: A method and apparatus for the continuous fabrication of fiber-bundle-based and composite-tape based preforms and preform charges includes a mandrel about which a constituent material, which is maintained under tension, is wound. The tension is insufficient to fully consolidate the wound material.

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

Abstract: A fiber-composite part having one or more electronic components that are located in arbitrary regions of the internal volume of the part are fabricated using a preform charge. The preform charge has a structure that corresponds to that of the mold cavity in which the part is being formed. By incorporating the electronic components in the preform charge, such components are then precisely located, spatially oriented, and constrained, and such location and orientation is maintained during molding to produce a part with the electronic components in the desired locations and orientations within its internal volume.

Abstract: A method for bonding thermoplastic fiber-composite parts comprises providing surface texture on one or both parts being bonded, and/or providing both parts with engagement features. Such surface textures and engagement features have a specific geometry and fiber alignment that facilitate fibrous interlock between the two parts at a bonding interface via in-situ consolidation.

Abstract: A method for forming a composite part involves forming a layup comprising (a) preforms/flat form-factor feedstock, either of which includes a plurality of fibers and a matrix precursor, and (b) a differential-melt polymer. The matrix precursor and the differential-melt polymer differ as to at least one of thermal properties and rheological properties. The layup is subjected to controlled application of heat and pressure to melt the matrix precursor and differential-melt polymer. The polymers are then cooled to form a composite part that displays properties attributable to all the constituents. As a function of a variety of factors, the resulting part can be homogenous or heterogenous, and the properties can be localized or global throughout the part.

Abstract: A system and methods are disclosed for producing components via additive manufacturing. In one embodiment, a three-dimensional geometry is sliced using a slicing plane to obtain a first two-dimensional geometry. A first polyline is generated based on a first skeleton of the first two-dimensional geometry, and a first slender body is generated based on the first polyline. The first slender body is subtracted from the first two-dimensional geometry to obtain a second two-dimensional geometry. A second polyline is generated based on a second skeleton of the second two-dimensional geometry. A first bundle of fibers is produced based on a segmentation of the first polyline and a second bundle of fibers is produced based on a segmentation of the second polyline. A component is produced from the first and second bundles of fibers using an additive manufacturing process.

Abstract: A method for rapid heat cycle compression molding comprises placing an assemblage of feed constituents in a mold, placing the mold between two hot platens of a hot press, heating the mold by pressing the two hot platens against the mold, placing the mold between two cold platens of a cold press, cooling the mold by pressing the two cold platens against the mold, and ejecting the part from the mold.

Abstract: A method for bending towpreg to yield a desired amount of axial force during bending to form a preform is provided including inserting towpreg into a bending die, applying an initial axial force to the towpreg, and moving the gripped end of the towpreg in an involute path using a cam, a cam follower and a gripper, the gripper disposed on the cam follower. Axial force between the gripped end and the stationary end of the towpreg from a point where the towpreg contacts a surface of the bending die is applied tangent to the surface of the bending die while bending the towpreg. An apparatus for bending towpreg to form a preform is provided including bending dies disposed in fixed positions, and a follower. Axial involute cam mechanism having a drive shaft, a cam, a cam follower that follows an involute path around the cam, a gripper and a clamp.

Abstract: An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.