Abstract: This invention involves the incorporation of gas in the matrix of a mandrel. The incorporation of gas, as foam, into the matrix of a mandrel reduces the density of the mandrel. The resulting mandrel is easier to remove from finished product by washout or disintegration. Therefore it is of great value in the use of mandrels in making hollow composite parts.

Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.

Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

Abstract: A tooling system may include an outer mold line (OML) tool and one or more inner mold line (IML) tools. The OML tool may have an OML tool surface. Each one of the IML tools may have an IML tool surface and may be receivable within the OML tool 202. Each IML tool may be formed of expandable material. Each IML tool may apply an internal compaction pressure to a composite assembly positioned between the OML tool surface and the IML tool surface when the expandable material is heated.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof. The mandrel can be a self-expanding mandrel, and can be used in a process or system for the manufacture of composite structures.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof. The mandrel can be a self-expanding mandrel, and can be used in a process or system for the manufacture of composite structures.

Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.

Abstract: A vacuum bagging system may include a layer assembly defining a fluid flow channel. The layer assembly may include a contact layer mounted to a composite part positionable within an outer mold line (OML) tool. The contact layer may have a contact layer width defined by opposing contact layer side edges. The layer assembly may further include an inner layer mounted to the contact layer and having inner layer side edges located between the contact layer side edges. The fluid flow channel may extend along at least a portion of the composite part to at least one part end. The vacuum bagging system may include an internal vacuum bag positionable against the inner layer. An inner mold line (IML) tool may support the internal vacuum bag. The contact layer width may be less than an IML tool width.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also be include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.

Abstract: A method of fabricating a three-dimensional printed part includes injecting a powder layer with an aqueous solution and curing the powder layer by depositing an acid gas on the powder layer to form a rigid structure.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof. The mandrel can be a self-expanding mandrel, and can be used in a process or system for the manufacture of composite structures.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also be include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.

Abstract: A method of fabricating a three-dimensional printed part includes injecting a powder layer with an aqueous solution and curing the powder layer by depositing an acid gas on the powder layer to form a rigid structure.

Abstract: A method for forming a composite structure, using a mandrel that is later removed from the composite structure, involves production of a mandrel by depositing a particulate mixture, including an aggregate and a binder, into a mold and removing the mandrel from the mold. The mandrel may be treated while still in the mold by heating, curing with an agent, microwave energy, or by some combination thereof. Once finished, the mandrel can be used in manufacturing polymer and/or composite components. The mandrel can also be include materials that can be easily removed from the finished composite structure by water, shakeout, chemically dissolving, or by some combination thereof.