Abstract: A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.

Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A method of fabricating a conformal deltoid noodle includes providing a composite prepreg material having a predetermined length and a width, the predetermined length being aligned along a longitudinal axis; subjecting the composite prepreg material to a cutting process to form a notched section coextensive along the predetermined length; and rolling the composite prepreg material along its width to create the conformal deltoid noodle.

Abstract: A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

Abstract: A method of fabricating a conformal deltoid noodle includes providing a composite prepreg material having a predetermined length and a width, the predetermined length being aligned along a longitudinal axis; subjecting the composite prepreg material to a cutting process to form a notched section coextensive along the predetermined length; and rolling the composite prepreg material along its width to create the conformal deltoid noodle.

Abstract: A method of sealing between two components includes applying and curing a layer of fay surface sealant to a first component. A layer of liquid shim is applied to one or more of the first component and a second component. The first component is assembled to the second component with the layer of fay surface sealant and the layer of liquid shim therebetween. An assembly of two components includes a first component and a layer of fay surface sealant applied and cured to a first facing surface of the first component. A second component includes a second facing surface, such that the second facing surface and the layer of fay surface sealant define a gap therebetween. A layer of liquid shim is located between the second component and the layer of fay surface sealant thereby substantially filling the gap.

Abstract: A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, an assembly to apply bonding pressure to the plies at least at the core and trim areas and a clamping device external to the assembly to apply a clamping force to the vacuum bag and the plies.

Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, the surface including core and trim portions for respective correspondence with locations of the core and trim areas of the panel, a border between the core and trim portions defining a surface feature displaced from a plane of the core portion, a lock disposable proximate to the surface feature to increase a pre-bonding friction between the plies at the surface feature and an assembly to apply bonding pressure to the plies and the lock at least at the core and trim areas.

Abstract: A composite sandwich panel a first facing and a second facing over a core layer, the first and second facings having at least one fiberglass layer between an inner and an outer graphite layer.

Abstract: A composite sandwich panel a first facing and a second facing over a core layer, the first and second facings having at least one fiberglass layer between an inner and an outer graphite layer.