Abstract: A method of manufacturing a composite part having a curved or radiused corner to avoid wrinkling or bridging of outer-most composite plies during consolidation and cure, including laying up composite material on male or female tooling to form two flanges extending at a first angle relative each other and a curved or radiused corner extending between the two flanges. Then the method may include changing an orientation of one or both of the flanges of the composite material, such that the two flanges extend at a second included angle relative each other. The second included angle is smaller than the first angle. The method may also include a step of consolidating the composite material before, after, or during the step of changing the orientation of the composite material to the second angle, as well as a step of curing the composite material oriented at the second angle.

Abstract: A system and method for temporarily sealing holes in a perforated material layer of a composite acoustic panel so as to reduce potential migration of a release agent through the holes during a curing process and to reduce ingression of water through the holes during a subsequent testing process. The release agent is applied to a tool, the barrier layer is arranged over the release agent, and a lay-up of elements, beginning with the perforated layer, are arranged over the barrier layer prior to heating the lay-up to form the panel. The barrier layer may be a substantially solid film, such as a plastic or nylon film, having a width of at least approximately twelve inches and a low vapor permeability with regard to the release agent. After the testing process is complete, the barrier layer may be peeled from the panel.

Abstract: The disclosure relates to an apparatus and method for manufacturing a molded article from plastic material feedstock in a continuous manner. The plastic material feedstock is confined between endless belts that define molded surfaces of the article to be molded.

Abstract: An abrasive stream perforation (ASP) system and method for forming a plurality of perforations through a composite part. The ASP system may include a compressed air source, a particulate source, a valve, nozzles, and a positioning device. The valve is actuatable between an open state and a closed state. The compressed air and particulate are simultaneously forced through the valve in its open state and then forced through the nozzles and against the surface of the composite part, forming the perforations through the composite part. The support frame maintains the nozzles in a spaced relationship to each other and a selected distance away from the composite part. The positioning device is fixed to the support frame and actuates the support frame relative to the surface of the composite part for proper positioning of the nozzles and the resulting perforations.

Abstract: An abrasive stream perforation (ASP) system and method for forming a plurality of perforations through a composite part. The ASP system may include a compressed air source, a particulate source, a valve, nozzles, and a positioning device. The valve is actuatable between an open state and a closed state. The compressed air and particulate are simultaneously forced through the valve in its open state and then forced through the nozzles and against the surface of the composite part, forming the perforations through the composite part. The support frame maintains the nozzles in a spaced relationship to each other and a selected distance away from the composite part. The positioning device is fixed to the support frame and actuates the support frame relative to the surface of the composite part for proper positioning of the nozzles and the resulting perforations.

Abstract: A system and method for temporarily sealing holes in a perforated material layer of a composite acoustic panel so as to reduce potential migration of a release agent through the holes during a curing process and to reduce ingression of water through the holes during a subsequent testing process. The release agent is applied to a tool, the barrier layer is arranged over the release agent, and a lay-up of elements, beginning with the perforated layer, are arranged over the barrier layer prior to heating the lay-up to form the panel. The barrier layer may be a substantially solid film, such as a plastic or nylon film, having a width of at least approximately twelve inches and a low vapor permeability with regard to the release agent. After the testing process is complete, the barrier layer may be peeled from the panel.