Abstract: A wave spring comprises fiber in a thermoplastic resin matrix, and includes one or more annular wave-springs elements, or one or more curvilinear wave-spring elements. The annular wave-spring elements, which are arrayed in a stack, are not coupled to one another. A wave spring comprising annular wave-spring elements includes an alignment feature for establishing and maintaining the alignment of the wave spring elements. In a wave spring including curvilinear wave-spring elements, a first end of each curvilinear wave-spring element is attached to a first member and a second end of each curvilinear wave-spring element is attached to a second member, the plurality of curvilinear wave-spring elements being disposed between the two members. The plurality of curvilinear wave-spring elements in the array are positioned side by side, the array extending laterally along a length of the first member and second member, and providing a low-profile wave spring.

Abstract: A molding method for fabricating a composite part having inserts is provided including disposing preforms in a mold, each having co-aligned, resin-impregnated fibers, placing the inserts in the mold adjacent to at least one of the preforms, wherein each insert has securement features for receiving a portion of the co-aligned resin-impregnated fibers from at least one preform, and applying heat and pressure in an amount sufficient to consolidate the resin-impregnated fibers into a resin matrix, thereby forming the part, including consolidating the fibers and resin within the securement features. A fiber composite part is also provided including continuous, co-aligned fibers within a resin matrix, and at least one insert disposed in the matrix, the insert comprising at least one securement feature having a second plurality of the fibers therein, the second plurality of fibers extending into the resin matrix and overlapping with some of the first plurality of fibers.