Abstract: A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

Abstract: A molding system and methods of forming a structure are presented. A molding system is configured to form a composite structure. The molding system comprises a first tool comprising a first vacuum groove, a first trough having a first edge configured to form a first bend of the composite structure, and a first molding surface; and a second tool comprising a second vacuum groove, a second trough having a second edge configured to form a second bend of the composite structure, and a second molding surface.

Abstract: A molding system and methods of forming a structure are presented. A molding system is configured to form a composite structure. The molding system comprises a first tool comprising a first vacuum groove, a first trough having a first edge configured to form a first bend of the composite structure, and a first molding surface; and a second tool comprising a second vacuum groove, a second trough having a second edge configured to form a second bend of the composite structure, and a second molding surface.

Abstract: A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

Abstract: A method of infusing liquid resin into a preform involves positioning a preform on a planar section of a tool surface and a trough section of the tool surface, where the planar section of the tool surface is positioned vertically above the trough section of the tool surface and with there being a plurality of grooves in the planar section of the tool surface and a bottom of the trough section of the tool surface. At least one of a fluid impervious sheet, a second tool and a vacuum bag is secured on the tool surface over the preform forming a sealed volume on the tool surface. A pressure differential and a flow of resin is supplied onto the tool surface and the liquid resin is infused into the preform by the pressure differential.

Abstract: A tool and its method of use, where a plurality of grooves are formed into the tool surface of the tool. The grooves have different cross-section dimensions, different lengths, different configurations and/or different patterns that function as tool surface resin distribution grooves. The grooves distribute and deliver resin supplied to the tool surface throughout a dry fiber composite layup positioned on the tool surface in resin infusion and resin transfer molding. The grooves are formed in the tool surface extending to discrete areas on the tool surface to direct a flow of liquid resin to the discrete areas and infuse the dry fiber composite layup with the liquid resin at those discrete areas of the tool surface.

Abstract: A method for drawing a flexible sleeve over an elongated mandrel includes placing a ring within a lumen of the sleeve. A first end of the sleeve is fixed against movement relative to a first end of the mandrel. A first end portion of the sleeve is inverted over a first end portion of the mandrel so as to define a circumferential cuff in the sleeve, and the ring is positioned concentrically within the circumferential cuff. Using, e.g., a magnet, the ring is then urged longitudinally along the mandrel and toward an opposite, second end thereof, such that the sleeve is inverted over at least an outer surface of the mandrel.

Abstract: A method for drawing a flexible sleeve over an elongated mandrel includes placing a ring within a lumen of the sleeve. A first end of the sleeve is fixed against movement relative to a first end of the mandrel. A first end portion of the sleeve is inverted over a first end portion of the mandrel so as to define a circumferential cuff in the sleeve, and the ring is positioned concentrically within the circumferential cuff. Using, e.g., a magnet, the ring is then urged longitudinally along the mandrel and toward an opposite, second end thereof, such that the sleeve is inverted over at least an outer surface of the mandrel.