Abstract: Processes for fabricating secondary structures of gas turbine engines from polymer-based materials, and secondary structures formed thereby. The processes entail performing an additive manufacturing technique to produce a secondary structure of a gas turbine engine. The additive manufacturing technique directly produces the secondary structure from a polymer-based material to have a complex three-dimensional shape characterized by portions that lie in different planes.

Abstract: Load-bearing structures constructed from polymer matrix composite (PMC) materials, and processes for their production. The structures are produced from at least one shaped panel formed of a continuous fiber reinforcement in a thermoplastic resin matrix. The shaped panel has been thermoformed to have a substantially constant cross-sectional thickness and portions that lie in different planes and are interconnected by one or more bends. The shaped panel is machined to alter its shape, and optionally to produce multiple separate subcomponents therefrom. The machined shaped panel can constitute the entire structure, or the structure can be formed by joining the machined shaped panel with other shaped panels or by joining two or more of the subcomponents. The structure can be installed on an aircraft engine to secure components to the engine.