Abstract: Systems and methods are provided for enhanced vacuum bags. One embodiment is a method that includes placing a laminate comprising uncured fiber reinforced polymer onto a mandrel, laying up a vacuum bag, which includes integral ultrasonic transducers within a gas-impermeable layer, atop the laminate, and sealing the vacuum bag to the mandrel. The method also includes drawing a vacuum on the laminate via the vacuum bag, removing gas between the integral ultrasonic transducers and the laminate, and interrogating the laminate with the integral ultrasonic transducers.

Abstract: Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.

Abstract: There is provided an automated lamination system for embedding printed electronic element(s) in a composite structure. The automated lamination system includes a supply of composite prepreg material, a layup tool assembly, and a modified automated lamination apparatus laying up layer(s) of the composite prepreg material on the layup tool assembly, to form the composite structure. The modified automated lamination apparatus includes a section preparation pre-printing apparatus preparing section(s) on a top surface of a top layer of the layer(s), to obtain prepared section(s), and includes a non-contact direct write printing apparatus mechanically coupled to the section preparation pre-printing apparatus, and includes one or more supplies of electronic element materials, printed with the non-contact direct write printing apparatus, on each of the prepared section(s), to obtain the printed electronic element(s), that are embedded in the composite structure.

Abstract: Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.

Abstract: Systems and methods are provided for fabrication of enhanced carbon fiber laminates that utilize encapsulated catalyst. One embodiment is a method that includes acquiring a batch of dry fibers, and acquiring a batch of catalyst capsules that each comprise catalyst that accelerates polymerization of monomers of a resin, and a shell that encapsulates the catalyst and liquefies at a curing temperature. The method further includes interspersing the catalyst capsules among the dry fibers, and impregnating the fibers with the resin after interspersing the catalyst capsules with the fibers.

Abstract: A method and apparatus for manufacturing a carbon fiber. Pressure is applied to a filament to change a cross-sectional shape of the filament and create a plurality of distinct surfaces on the filament. The filament is converted into a graphitic carbon fiber having the plurality of distinct surfaces. A plurality of sizings is applied to the plurality of distinct surfaces of the graphitic carbon fiber in which the plurality of sizings includes at least two different sizings.

Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method of forming a composite part. The method includes laying up opposing composite facesheets, placing a viscous material between the facesheets, increasing a distance between the facesheets, and solidifying the facesheets and the viscous material into an integral composite part.

Abstract: A chemical vapor deposition method comprises flowing a carrier liquid through a reactor. A fluid comprising one or more reactants is introduced into the carrier liquid. The fluid is at a first temperature and first pressure and is sufficiently immiscible in the carrier liquid so as to form a plurality of microreactors suspended in the carrier liquid. Each of the microreactors comprise a discrete volume of the fluid and have a surface boundary defined by an interface of the fluid with the carrier liquid. The fluid is heated and optionally pressurized to a second temperature and second pressure at which a chemical vapor deposition reaction occurs within the microreactors to form a plurality of chemical vapor deposition products. The plurality of chemical vapor deposition products are separated from the carrier liquid. A system for carrying out the method of the present disclosure is also taught.

Abstract: A deployable airborne sensor array system and method of use are provided herein. The system includes a tether configured to be coupled to and deployed from an aircraft and a plurality of airborne vehicles coupled to the tether. Each of the plurality of airborne vehicles includes different lift characteristics to form a three-dimensional (3D) array of airborne vehicles. Each airborne vehicle includes a sensing device configured to generate sensor data associated with a target. The system also include a computing device configured to process the sensor data received from each of the plurality of airborne vehicles and generate an image of the target based on the sensor data.

Abstract: Methods, systems, and apparatuses are disclosed for the selective and controlled removal of debris from specific areas of a substrate outer surface without adversely impacting the substrate outer surface, including substrate outer surface coatings, and returning an actual substrate outer surface profile containing affixed debris to a predetermined substrate outer surface profile by comparing a library of predetermined profiles to an actual substrate outer surface profile in real time.

Abstract: Autonomous craft capable of extended duration operations as lighter-than-air craft, having the ability to alight on the surface of a body of water and generate hydrogen gas for lift via electrolysis using power derived from a photovoltaic system, as well as methods of launching an unmanned aerial vehicle (UAV) having a deployable envelope from a surface of a body of water.

Abstract: A fastener includes a head that is configured to be engaged by a tool, and a shaft extending from the head. The shaft includes a distal end that is opposite from the head. At least one optical component is coupled to one or both of the head or the shaft. The optical component(s) is configured to allow light to pass through the fastener. A window system includes a panel that includes an exterior surface and an interior surface, and the fastener extending between the exterior surface and the interior surface of the panel. A screen is coupled to the interior surface. The screen receives light from the optical component(s) of the fastener.

Abstract: Composite materials having carbon reinforcement fibers impregnated with a matrix material are augmented with functionalized graphene nanoplatelets having amine groups formed on a surface of the graphene nanoplatelets and epoxide groups formed on at least one edge of the graphene nanoplatelets as a supplement to or a replacement for resin matrix material to increase strength of the composite materials. Related methods of increasing strength of composite materials include mixing the functionalized graphene nanoplatelets into the matrix material prior to impregnating the carbon reinforcement fibers, depositing the functionalized graphene nanoplatelets onto the matrix material to form an interlayer, and depositing the functionalized graphene nanoplatelets onto a bed of carbon reinforcement fibers with no resin matrix material. The composite materials and related methods for increasing strength of composite materials may include graphene nanoplatelets having holes formed through the graphene nanoplatelets.

Abstract: There is provided an automated lamination system for embedding printed electronic element(s) in a composite structure. The automated lamination system includes a supply of composite prepreg material, a layup tool assembly, and a modified automated lamination apparatus laying up layer(s) of the composite prepreg material on the layup tool assembly, to form the composite structure. The modified automated lamination apparatus includes a section preparation pre-printing apparatus preparing section(s) on a top surface of a top layer of the layer(s), to obtain prepared section(s), and includes a non-contact direct write printing apparatus mechanically coupled to the section preparation pre-printing apparatus, and includes one or more supplies of electronic element materials, printed with the non-contact direct write printing apparatus, on each of the prepared section(s), to obtain the printed electronic element(s), that are embedded in the composite structure.

Abstract: Composite laminate parts are made using a gradient cured subset of fiber reinforced thermoset resin plies. A portion of the subset is cured to rigidity to thereby maintain the shape of a part layup, while other plies in the subset are actively cooled to prevent them from curing. Additional plies are laid up on the uncured plies of the subset to complete the layup. The completed layup is then fully cured.

Abstract: A dimmable window apparatus is provided. The dimmable window apparatus includes a window including a first linear polarizing film and a second linear polarizing film, the first linear polarizing film and the second linear polarizing film having respectively a first axis of polarization and a second axis of polarization, the second axis of polarization being electronically-controllable. The apparatus further includes a processor coupled to the second linear polarizing film, and configured to control the second axis of polarization to thereby control the opacity of the window that is defined by the first axis of polarization and the second axis of polarization relative to one another.

Abstract: Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.

Abstract: Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.

Abstract: A composite structure forming system configured to form a contoured elongate composite structure in a continuous process is presented. The composite structure forming system comprises a plurality of charge forming stations and a plurality of conveyor systems. The plurality of charge forming stations is configured to operate in parallel, each charge forming station of the plurality of charge forming stations is configured to form a respective composite charge of the contoured elongate composite structure. Each conveyor system of the plurality of conveyor systems is configured to transport a respective composite charge through a respective charge forming station.

Abstract: Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a location for placing the composite part on the tool, and to direct the dispensers to lay up a laminate of constituent material for the composite part at the location. The controller is also able to direct the dispensers to spray vacuum bag material atop the laminate to form a vacuum bag that covers the laminate.