Abstract: A method of manufacturing a composite component having an outer shell, an inner hub, and a plurality of struts connecting the outer shell and the inner hub. An initial outer shell hoop preform is woven and includes a plurality of bifurcated strut portions on an exterior side of the initial outer shell hoop preform. The initial outer shell hoop preform is turned inside-out to form a woven outer shell hoop preform so that the bifurcated strut portions are arranged on the interior side to extend inward. The woven outer shell hoop preform is installed on a mold tooling structure, along with an inner hub preform, and the bifurcated strut portions are connected to inner hub pi-joint members of the inner hub preform. A matrix material is injected into the mold tooling structure and a curing process is applied to the mold tooling structure to obtain the composite component.

Abstract: A method of manufacturing a composite component including an outer shell, an inner hub, and a plurality of struts connecting the outer shell and the inner hub. The method includes installing an outer shell hoop preform on a mold tooling structure, installing an inner hub hoop preform on the mold tooling structure, and inserting strut preforms through outer shell strut slots, and through inner hub strut slots. A first end of the strut preform has bifurcated end portions that are overlayed onto the outer shell hoop preform, and a second end of the strut preform has bifurcated end portions that are overlayed onto one of the outer shell hoop preform or the inner hub hoop preform. A matrix material is injected into the mold tooling structure and a curing process is applied to the mold tooling structure to obtain a molded composite component.

Abstract: A preform for making a casing structure for turbine engines. The preform includes a plurality of reinforcing fiber tows arranged in a two-dimensional weave structure, a three-dimensional weave structure, or a braided structure. The plurality of reinforcing fiber tows include integrally woven or braided fiber tows having a diameter or a density greater than a respective diameter or density of other woven or braided fiber tows in the two-dimensional weave structure, the three-dimensional weave structure, or the braided structure. The integrally woven or braided fiber tows are located in an area of the preform that is bent to form an angled corner to thereby provide strength to a casing structure comprising the angled corner.