Abstract: A method of fabricating a composite part with integral structural details is provided. Fibrous material may be wrapped on a detail surface and an interface surface of a first detail mold. Fibrous material may also be wrapped on a detail surface and an interface surface of a second detail mold. Fibrous material may also be laid on a molding surface of a tool mold to form a control surface of the part. The first and second detail molds may be arranged on the molding surface of the tool mold to form the details. In particular, fibrous material wrapped on the detail surfaces of the first and second detail molds may be disposed adjacent to each other, and fibrous material wrapped on the interface surfaces of the first and second detail molds may be disposed adjacent to the fibrous material laid on the molding surface. Resin is flowed into the detail molds via inlet ports and through integral resin channels into the fibrous material.

Abstract: In the field of vacuum-assist-resin-transfer-mold (VARTM) processing, a new system is provided to lower production times and to create a high permeability mold cavity with reduced directionality to yield an optimum flow-front. The system comprises the use of a high permeability layer to evacuate air from the mold cavity and may include a reusable port-runner device for introduction of resin into the fiber mat. In the preferred embodiment, the high permeability layer is a “felt-like” material constructed of synthetic fibers, and the reusable port device is a flat, modular unit. In another embodiment, the high permeability layer is a fluid-impervious material with sporadic protrusions, and the reusable port-runner device is a flexible, silicone unit. Other embodiments are comprised of any combination thereof. Each embodiment is designed to minimize set-up times and to create a mold cavity with a low resistance to fluid flow through the application of pressure differentials.

Abstract: In the field of vacuum-assist-resin-transfer-mold (VARTM) processing, a new system is provided to lower production times and to create a high permeability mold cavity with reduced directionality to yield an optimum flow-front. The system comprises the use of a high permeability layer to evacuate air from the mold cavity and may include a reusable port-runner device for introduction of resin into the fiber mat. In the preferred embodiment, the high permeability layer is a “felt-like” material constructed of synthetic fibers, and the reusable port device is a flat, modular unit. In another embodiment, the high permeability layer is a fluid-impervious material with sporadic protrusions, and the reusable port-runner device is a flexible, silicone unit. Other embodiments are comprised of any combination thereof. Each embodiment is designed to minimize set-up times and to create a mold cavity with a low resistance to fluid flow through the application of pressure differentials.