Abstract: An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.

Abstract: An aircraft includes a composite structure, comprising an outer skin formed from a composite material and having a first thickness, an inner skin formed from a composite material and having a second thickness, the second thickness being greater than the first thickness, and a core structure positioned between the inner and outer skins to increase bending stiffness of the composite structure. During use a structural load carried by the inner skin exceeds a structural load carried by the outer skin.

Abstract: A method of making a core-stiffened structure includes the steps of providing a honeycomb core having an adhesive disposed on first and second surfaces thereof, providing a first skin and a second skin, and assembling the first skin, the second skin, and the honeycomb core to form the core-stiffened structure. The method further includes the steps of curing the core-stiffened structure and inhibiting at least one of the first skin and the second skin from protruding into at least one cell of the honeycomb core during the step of curing the core-stiffened structure.

Abstract: A method of making a core-stiffened structure includes the steps of providing a honeycomb core having an adhesive disposed on first and second surfaces thereof, providing a first skin and a second skin, and assembling the first skin, the second skin, and the honeycomb core to form the core-stiffened structure. The method further includes the steps of curing the core-stiffened structure and inhibiting at least one of the first skin and the second skin from protruding into at least one cell of the honeycomb core during the step of curing the core-stiffened structure.

Abstract: An apparatus for attaching a member to a honeycomb core-stiffened structure includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of a honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus. A honeycomb core-stiffened structure includes a honeycomb core and an apparatus for attaching a member to the honeycomb core. The apparatus includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of the honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus.

Abstract: An aircraft includes a composite structure, comprising an outer skin formed from a composite material and having a first thickness, an inner skin formed from a composite material and having a second thickness, the second thickness being greater than the first thickness, and a core structure positioned between the inner and outer skins to increase bending stiffness of the composite structure. During use a structural load carried by the inner skin exceeds a structural load carried by the outer skin.

Abstract: A composite core includes a plurality of tubes, each the plurality of tubes comprising a plurality of fibers disposed in a polymeric matrix. Adjacent tubes of the plurality of tubes are adhesively bonded to one another along sides of the adjacent tubes. A method of making a composite core includes the steps of providing a plurality of tubes, each of the plurality of tubes including a plurality of fibers disposed in a polymeric matrix, and adhesively bonding adjacent tubes of the plurality of tubes along sides of the adjacent tubes. A method of making a composite core such that a removable band is included in the core, the removable band being configured to be removable through a procedure subsequent to the cure of the composite core, thereby producing gaps in the core.

Abstract: A composite core includes a plurality of tubes, each the plurality of tubes comprising a plurality of fibers disposed in a polymeric matrix. Adjacent tubes of the plurality of tubes are adhesively bonded to one another along sides of the adjacent tubes. A method of making a composite core includes the steps of providing a plurality of tubes, each of the plurality of tubes including a plurality of fibers disposed in a polymeric matrix, and adhesively bonding adjacent tubes of the plurality of tubes along sides of the adjacent tubes. A method of making a composite core such that a removable band is included in the core, the removable band being configured to be removable through a procedure subsequent to the cure of the composite core, thereby producing gaps in the core.

Abstract: A method of making a core-stiffened structure includes the steps of providing a honeycomb core having an adhesive disposed on first and second surfaces thereof, providing a first skin and a second skin, and assembling the first skin, the second skin, and the honeycomb core to form the core-stiffened structure. The method further includes the steps of curing the core-stiffened structure and inhibiting at least one of the first skin and the second skin from protruding into at least one cell of the honeycomb core during the step of curing the core-stiffened structure.

Abstract: An apparatus for joining a first member and a second member includes fasteners for joining the first member and the second member, a shear transfer layer for transferring shear loads between the first member and the second member separate from the fasteners for joining the first member and the second member. An assembly includes a first member, a second member, and fasteners for joining the first member and the second member. The assembly further includes a shear transfer layer for transferring shear loads between the first member and the second member separate from the fasteners for joining the first member and the second.

Abstract: An apparatus for attaching a member to a honeycomb core-stiffened structure includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of a honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus. A honeycomb core-stiffened structure includes a honeycomb core and an apparatus for attaching a member to the honeycomb core. The apparatus includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of the honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus.

Abstract: A method of making a core-stiffened structure includes the steps of providing a honeycomb core having an adhesive disposed on first and second surfaces thereof, providing a first skin and a second skin, and assembling the first skin, the second skin, and the honeycomb core to form the core-stiffened structure. The method further includes the steps of curing the core-stiffened structure and inhibiting at least one of the first skin and the second skin from protruding into at least one cell of the honeycomb core during the step of curing the core-stiffened structure.

Abstract: A method of carving a contour surface on a composite core can include positioning a first edge of the composite core against a first tooled member; locating a first magnet within an outer cell member along the first edge of the composite core so that the first edge of the composite core is magnetically drawn to the first tooled member; locating a second magnet along a second edge of the composite core such that the second edge of the composite core is magnetically drawn to a second tooled member; and carving a first contour of the composite core.

Abstract: An apparatus for attaching a member to a honeycomb core-stiffened structure includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of a honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus. A honeycomb core-stiffened structure includes a honeycomb core and an apparatus for attaching a member to the honeycomb core. The apparatus includes a body and one or more elements extending from the body configured to be adhesively bonded to one or more walls of the honeycomb core of the honeycomb core-stiffened structure. The apparatus further includes a fitting for attaching the member to the apparatus.

Abstract: A method of assembling a core stiffened structure that includes bonding a composite core to a substructure by utilizing magnetic force to create pressure between a flat surface of the composite core the substructure, and bonding a face sheet onto a surface network of the composite core.

Abstract: A method of wrapping a plurality of mandrels with a composite material can include rotating each mandrel at a rotational speed; translating each mandrel at a translation speed; positioning each mandrel back to back such that an aft face of a preceding mandrel is approximate to a forward face of a trailing mandrel; and sequentially wrapping each mandrel with the composite material in a helical orientation.

Abstract: A method of making a composite core can include configuring a plurality of mandrels to have a desired thermal expansion characteristic, placing a composite material around each mandrel, placing the plurality of mandrels in a tool, the tool being configured to constrain the plurality of mandrels as the mandrels experience a thermal expansion, heating the mandrels so that the mandrels thermally expand, thereby applying a pressure to the composite material during a cure cycle, and then cooling and separating the mandrels from the composite core. The mandrel is configured as an internal form for making a tube member of a composite core.

Abstract: A method of splicing together a first composite core and a second composite core can include: positioning a first flange of the first composite core adjacent to a second flange of the second composite core, applying an adhesive, and locating a first magnet and a second magnet to provide a pressure on the adhesive.

Abstract: A method of splicing together a first composite core and a second composite core can include: positioning a first flange of the first composite core adjacent to a second flange of the second composite core, applying an adhesive, and locating a first magnet and a second magnet to provide a pressure on the adhesive.

Abstract: A method of assembling a core stiffened structure that includes bonding a composite core to a substructure by utilizing magnetic force to create pressure between a flat surface of the composite core the substructure, and bonding a face sheet onto a surface network of the composite core.