Abstract: A tooling assembly and method for forming a flange of a composite component is provided. The tooling assembly includes a mold configured to receive a composite material. The composite material may include a plurality of fabric plies impregnated with resin. The fabric plies may be debulked as they are being laid using a plurality of debulking tools, with the radius of each debulking tool growing as additional fabric plies are laid. A gas-permeable bagging material may be placed along the edge of the composite material to restrict resin flow while allowing for outgassing. The tooling assembly may further include a flange shoe tool that is joined with the mold to form the flange of the composite material. The mold and flange shoe tool may define a chamber and venting passageways that allow gases such as volatile compounds to escape while the composite component is being cured.

Abstract: Method includes forming a preform utilizing a polyimide resin-impregnated fiber-reinforced layers; removing solvent from the system at initial vacuum, pressure, and temperature conditions for an initial time interval sufficient to remove substantially all the solvent; imidizing the polyimide resin system under second vacuum, pressure, and temperature conditions for a second time interval sufficient to substantially completely imidize the polyimide resin; consolidating the preform following imidization under third vacuum, pressure, and temperature conditions and including applying pressure to the preform when the preform is at a predetermined temperature; and solidifying the preform under fourth vacuum, pressure, and temperature conditions to provide a cured laminate structure having a shape of a turbine engine component.