Abstract: A method for manufacturing a C/C part includes fabricating an oxidized PAN fiber preform comprising a stack of sheets of multi-axial, non-crimp, OPF fabric. The method includes positioning the oxidized PAN fiber preform with a female forming tool, the female forming tool comprising a die recess, and forming the oxidized PAN fiber preform into a shaped body. The shaped body is removed from the female forming tool and moved into a graphite fixture for carbonization. The carbonized shaped body may also be densified into the final C/C part. The carbonized shaped body can also be placed in a perforated graphite fixture for densification and removed from the perforated graphite fixture between densification processes for machining and for facilitating further densification.

Abstract: A preform is provided. The preform includes first fabric layers that include a first set of commingled fibers and a second set of commingled fibers. The preform includes a second fabric layer positioned between the first fabric layers. The second fabric layer includes a third set of commingled fibers and a fourth set of commingled fibers. The first set of commingled fibers includes a lower percentage of the at least one of first carbon fibers or first fusible fibers than the third set of commingled fibers, The first set of commingled fibers include a higher percentage of first fugitive fibers than the third set of commingled fibers. The first fugitive fibers and the third fugitive fibers are pyrolyzed from the first fabric layers and the second fabric layer.

Abstract: A system for forming a preform into a shaped body includes an inner mold line, a caul plate, a plurality of compressing bladders mounted to the caul plate, and a floating plate coupled to a side of the inner mold line. The floating plate is configured to receive an end of the preform and translate in a first direction to tension the preform into the shaped body.

Abstract: A manufacturing method is provided. The manufacturing method applies a bonding adhesive to at least one of the first surface of the first composite preform component or the first surface of the second composite preform component, and joins the first surface of the first composite preform component to the first surface of the second composite preform component.

Abstract: A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is pressed into a grip strip coupled to a side of the inner mold line. The grip strip is translated in a first direction to tension the preform into a shaped body.

Abstract: A method for performing a through thickness reinforcement process on a fibrous preform includes moving a plurality of needles from a retracted position to an extended position with respect to a housing. The method further includes penetrating a veil cloth and the fibrous preform with the plurality of needles, moving a through thickness fiber from the veil cloth at least partially into the fibrous preform in response to the fibrous preform being penetrated with the plurality of needles, moving the plurality of needles from the extended position to the retracted position, rotating a feeder spool and a take up spool to move the veil cloth with respect to the fibrous preform, and lifting a needled portion of the veil cloth from the fibrous preform in response to the feeder spool and the take up spool rotating.

Abstract: A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is clamped to a floating plate using a bladder-activated clamp. The floating plate is translated in a first direction to tension the preform into a shaped body. A plurality of compressing bladders are activated to apply compressive forces to the preform.

Abstract: A commingled fiber preform is provided. The commingled fiber preform includes a plurality of first fabric layers and a second fabric layer. The second fabric layer is positioned on top of the plurality of first fabric layers. The second fabric layer is joined to the plurality of first fabric layers via through thickness reinforcement (TTR) using a commingled thread. A transport depth of the TTR penetrates completely through a thickness of the second fabric layer and partially through a thickness of the plurality of first fabric layers. The commingled thread comprises carbon fibers commingled with fugitive fibers. The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids.

Abstract: A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is pressed into a grip strip coupled to a side of the inner mold line. The grip strip is translated in a first direction to tension the preform into a shaped body.

Abstract: A commingled fiber preform is provided. The commingled fiber preform includes at least one first fabric layer and a second fabric layer. The second fabric layer is positioned on top of the at least one first fabric layer. The second fabric layer is joined to the at least one first fabric layer via through thickness reinforcement (TTR) using a commingled thread. A transport depth of the TTR penetrates completely through a thickness of the second fabric layer and an entirety of the at least one first fabric layer. The commingled thread comprises carbon fibers commingled with fugitive fibers. The fugitive fibers are pyrolyzed from the commingled fiber preform to create a path through the thickness for infiltration of fluids.

Abstract: A manufacturing method is disclosed herein. The method includes arranging a preform with a plurality of clamping assemblies, the plurality of clamping assemblies disposed along ends of the preform; and forming the preform into a shaped body, the forming including incrementally tensioning the preform around a surface of an inner mold line using the plurality of clamping assemblies; and drawing the preform into a set of forming beads of the inner mold line.

Abstract: A manufacturing method is provided. The manufacturing method arranges a first surface of a first composite preform component to align with a first surface of a second composite preform component; attaches the first surface of the first composite preform component to the first surface of the second composite preform component to form a complex composite structure; and densifies the complex composite structure as one, complete complex composite structure.

Abstract: Systems and methods for through thickness reinforcement of a fibrous preform include a needle configured to move a through thickness fiber along a curved path. The needle can be moved along the curved path and can penetrate one or more plies of the fibrous preform. The needle can move one or more through thickness fibers along the curved path (e.g., from a first ply of the fibrous preform at least partially into a second ply of the fibrous preform). The needle can be moved about one or more axes during through thickness reinforcement. In various embodiments, the needle is translated along an axis, and rotated about the same axis to move the through thickness fiber(s) along the curved path.

Abstract: A method for selective needling on a fibrous preform includes performing a through thickness reinforcement process on the fibrous preform and varying a needle density, a needle angle, and/or a needle penetrating depth during the through thickness reinforcement process such that a first needle density, a first needle angle, and/or a first needle penetrating depth of a first zone of the fibrous preform is greater than a second needle density, a second needle angle, and/or a second needle penetrating depth of a second zone of the fibrous preform. The method can further include identifying expected interlaminar stress throughout the fibrous preform and varying the needle density, needle angle, and/or needle penetrating depth in accordance with a magnitude of the expected interlaminar stress.

Abstract: A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a first die half configured to be received by the die recess, a second die half configured to be received by the die recess, an expander tool coupled between the first die half and the second die half. The expander tool is configured to move the first die half laterally toward a first side of the female forming tool away from the second die half to compress the fibrous preform between the first die half and the female forming tool. The expander tool is further configured to move the second die half laterally toward a second side of the female forming tool away from the first die half to compress the fibrous preform between the second die half and the female forming tool.

Abstract: An end effector for needling a fibrous preform includes a body (or head), a plurality of articulating presser feet mounted to the body and moveable with respect to the body, and a plurality of articulating needles mounted to the body and moveable with respect to the body. The needles may be configured to move between an extended position and a retracted position. The presser feet may be configured to move between an extended position and a retracted position. The end effector presser feet may conform to complex geometries of a fibrous preform. The end effector may control needling depth, needling density, applied tension and/or pressure on the fibrous preform, and needle angle.

Abstract: A preform tooling arrangement includes a base plate comprising a male die surface and a stripper plate comprising a female die surface. A plurality of perforations are disposed in the base plate and/or the stripper plate. The stripper plate is moveable with respect to the base plate. The preform tooling arrangement is configured to receive a fibrous preform between the male die surface and the female die surface. The preform tooling arrangement is a dual-purpose fixture configured to accommodate z-needling and densification, all while the fibrous preform remains in the same fixture (i.e., the preform tooling arrangement). The perforations are configured to receive one or more textile needles for through thickness reinforcement of the fibrous preform.

Abstract: A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a support structure moveable with respect to the female forming tool, and at least one bladder coupled to the support structure and configured to be received into the die recess. The support structure is configured to move the bladder(s) with respect to the female forming tool. The bladder(s) is/are configured to be inflated to apply a compressive force to compress and form a fibrous preform between the bladder(s) and the female forming tool.

Abstract: A method for performing a through thickness reinforcement process on a fibrous preform includes moving a plurality of needles from a retracted position to an extended position with respect to a housing. The method further includes penetrating a veil cloth and the fibrous preform with the plurality of needles, moving a through thickness fiber from the veil cloth at least partially into the fibrous preform in response to the fibrous preform being penetrated with the plurality of needles, moving the plurality of needles from the extended position to the retracted position, rotating a feeder spool and a take up spool to move the veil cloth with respect to the fibrous preform, and lifting a needled portion of the veil cloth from the fibrous preform in response to the feeder spool and the take up spool rotating.

Abstract: A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a support structure moveable with respect to the female forming tool, and at least one bladder coupled to the support structure and configured to be received into the die recess. The support structure is configured to move the bladder(s) with respect to the female forming tool. The bladder(s) is/are configured to be inflated to apply a compressive force to compress and form a fibrous preform between the bladder(s) and the female forming tool.