Abstract: An aircraft includes an airframe and a distributed thrust array coupled to the airframe including at least six propulsion assemblies. A flight control system is operably associated with the distributed thrust array and is operable to independently control each of the propulsion assemblies. A package delivery module is coupled to the airframe. In a VTOL orientation utilizing thrust-borne lift, a first pair of propulsion assemblies is forward of the package delivery module, a second pair of propulsion assemblies is aft of the package delivery module and a third pair of propulsion assemblies is lateral of the package delivery module. In a forward flight orientation utilizing wing-borne lift, the first pair of propulsion assemblies is below the package delivery module, the second pair of propulsion assemblies is above the package delivery module and the third pair of propulsion assemblies is lateral of the package delivery module.

Abstract: An aircraft having a vertical takeoff and landing fight mode and a forward flight mode. The aircraft includes an airframe and a versatile propulsion system attached to the airframe. The versatile propulsion system includes a plurality of propulsion assemblies. A flight control system is operable to independently control the propulsion assemblies. The propulsion assemblies are interchangeably attachable to the airframe such that the aircraft has a liquid fuel flight mode and an electric flight mode. In the liquid fuel flight mode, energy is provided to each of the propulsion assemblies from a liquid fuel. In the electric flight mode, energy is provided to each of the propulsion assemblies from an electric power source.

Abstract: An aircraft includes an airframe and a distributed propulsion system including a plurality of propulsion assemblies coupled to the airframe. Each of the propulsion assemblies includes a nacelle, an engine disposed within the nacelle, a proprotor coupled to the engine and a thrust vectoring system. Each thrust vectoring system includes a pivoting plate, a rotary actuator operable to rotate the pivoting plate about a propulsion assembly centerline axis and a linear actuator operable to pivot the pivoting plate about a pivot axis that is normal to the propulsion assembly centerline axis. The engine is mounted on the pivoting plate such that operation of the pivoting plate enables resolution of a thrust vector within a thrust vector cone.

Abstract: An aircraft operable to transition between a forward flight mode and a vertical takeoff and landing flight mode. The aircraft includes an airframe having first and second wings. A plurality of propulsion assemblies is attached to the airframe with each of the propulsion assemblies including a nacelle and a tail assembly having at least one active aerosurface. A flight control system is operable to independently control each of the propulsion assemblies. For each of the propulsion assemblies, the tail assembly is rotatable relative to the nacelle such that the active aerosurface has a first orientation generally parallel to the wings and a second orientation generally perpendicular to the wings.

Abstract: A method for forming composite components includes disposing composite laminate over a mandrel. The method further includes infusing the composite laminate with a resin. A gelation of the infused resin is caused by applying a first environmental condition to the composite laminate and mandrel. At least a portion of the mandrel is deformed by applying a second environmental condition to the composite laminate and mandrel. The method further includes forming a composite structure by curing the composite laminate infused with resin. The deformed mandrel is removed from the composite structure after forming the composite structure.

Abstract: A rotor assembly for an aircraft operable to generate a variable thrust output at a constant rotational speed. The rotor assembly includes a mast rotatable at the constant speed about a mast axis. A rotor hub is coupled to and rotatable with the mast. The rotor hub includes a plurality of spindle grips extending generally radially outwardly. Each of the spindle grips is coupled to one of a plurality of rotor blades and is operable to rotate therewith about a pitch change axis. A collective pitch control mechanism is coupled to and rotatable with the rotor hub. The collective pitch control mechanism is operably associated with each spindle grip such that actuation of the collective pitch control mechanism rotates each spindle grip about the respective pitch change axis to collectively control the pitch of the rotor blades, thereby generating the variable thrust output.

Abstract: A hybrid composite and metallic gear includes a generally cylindrical shaft interface. A composite web is coupled to the shaft interface. The composite web includes a generally cylindrical rim having an outer surface. The outer surface includes a plurality of locks each having a radially outwardly extending profile. A generally cylindrical metallic gear ring having a plurality of external teeth includes an inner surface. The inner surface includes a plurality of detents each having a radially outwardly extending profile that corresponds with one of the locks of the composite web. When the composite web is positioned within the metallic gear ring, the corresponding locks and detents each form a lock and detent coupling establishing an interlocking interface between the composite web and the metallic gear ring.

Abstract: An aircraft has a vertical takeoff and landing fight mode and a forward flight mode. The aircraft includes an airframe with first and second M-wings having first and second pylons extending therebetween, each M-wing forming a pair of leading apexes with swept forward and swept back portions extending therefrom at a swept angle. A propulsion system includes a plurality of propulsion assemblies each attached to the airframe proximate one of the leading apexes. Each of the propulsion assemblies includes a rotor assembly having a tilting degree of freedom. A flight control system is operable to control the propulsion assemblies including tilting the rotor assemblies to generate variable thrust vectors. In the vertical takeoff and landing fight mode, the aircraft operates responsive to thrust-borne lift from the propulsion system. In the forward flight mode, the aircraft operates responsive to wing-borne lift in a biplane orientation.

Abstract: A method is provided in one example embodiment and may include forming a ply stack on a tool, the ply stack comprising a plurality of plies; compacting the ply stack; and heating the ply stack during the compacting to form a composite structure, wherein the heating is caused by an electromagnetic inductive device or a radiative device. Compacting the ply stack can include encapsulating the ply stack within a bag and increasing a vacuum within the bag to increase external pressure on the bag and the ply stack.

Abstract: A composite core with non-traditional geometries includes multiple elongate tubes arranged in a two-dimensional array. Each tube is made of a composite material. Each tube includes multiple curved sides. Each curved side inwardly curves toward a longitudinal axis passing through a geometric center of the tube to form a valley on an outer surface of the tube. An end of a first curved side connects to an end of a second curved side to form a crest on the outer surface of the tube. At least one crest formed on an outer surface of a first tube in the two-dimensional array contacts at least one valley formed on an outer surface of an adjacent second tube in the two-dimensional array.

Abstract: An aircraft includes an airframe and a distributed propulsion system including a plurality of propulsion assemblies coupled to the airframe. Each of the propulsion assemblies includes a nacelle, an engine disposed within the nacelle, a proprotor coupled to the engine and a thrust vectoring system. Each thrust vectoring system includes a pivoting plate, a rotary actuator operable to rotate the pivoting plate about a propulsion assembly centerline axis and a linear actuator operable to pivot the pivoting plate about a pivot axis that is normal to the propulsion assembly centerline axis. The engine is mounted on the pivoting plate such that operation of the pivoting plate enables resolution of a thrust vector within a thrust vector cone.

Abstract: A rotor assembly for an aircraft operable to generate a variable thrust output at a constant rotational speed. The rotor assembly includes a mast rotatable at the constant speed about a mast axis. A rotor hub is coupled to and rotatable with the mast. The rotor hub includes a plurality of spindle grips extending generally radially outwardly. Each of the spindle grips is coupled to one of a plurality of rotor blades and is operable to rotate therewith about a pitch change axis. A collective pitch control mechanism is coupled to and rotatable with the rotor hub. The collective pitch control mechanism is operably associated with each spindle grip such that actuation of the collective pitch control mechanism rotates each spindle grip about the respective pitch change axis to collectively control the pitch of the rotor blades, thereby generating the variable thrust output.

Abstract: An aircraft includes a flying frame and a pod assembly that is selectively attached to the flying frame. The pod assembly has an aerodynamic outer shape. The flying frame includes an airframe having first and second wings, a propulsion system attached to the airframe and a flight control system operably associated with the propulsion system. The flying frame has a vertical takeoff and landing mode in which the first wing is forward of the pod assembly and the second wing is aft of the pod assembly. The flying frame has a forward flight mode in which the first wing is below the pod assembly and the second wing is above the pod assembly. The flying frame is operable for flight both with the pod assembly and without the pod assembly attached thereto. The flying frame is operable to jettison the pod assembly during flight.

Abstract: A composite core with non-traditional geometries includes multiple elongate tubes arranged in a two-dimensional array. Each tube is made of a composite material. Each tube includes multiple curved sides. Each curved side inwardly curves toward a longitudinal axis passing through a geometric center of the tube to form a valley on an outer surface of the tube. An end of a first curved side connects to an end of a second curved side to form a crest on the outer surface of the tube. At least one crest formed on an outer surface of a first tube in the two-dimensional array contacts at least one valley formed on an outer surface of an adjacent second tube in the two-dimensional array.

Abstract: An aircraft has a vertical takeoff and landing fight mode and a forward flight mode. The aircraft includes an airframe with first and second M-wings each having a pair of leading apexes with swept forward and swept back portions extending therefrom at a swept angle. A propulsion system includes a plurality of propulsion assemblies each attached to the airframe proximate one of the leading apexes. Each of the propulsion assemblies includes a rotor assembly having a tilting degree of freedom. A flight control system is operable to control the propulsion assemblies including tilting the rotor assemblies to generate variable thrust vectors that have a maximum angle that is generally congruent with the swept angles of the M-wings.

Abstract: Systems and methods of constructing a thermoplastic component include joining a thermoplastic skin to a thermoplastic core by introducing heat at an interface of each of the thermoplastic skin and the thermoplastic core to at least partially melt the thermoplastic skin to a thermoplastic core at the interfaces, applying pressure to at least one of the thermoplastic skin and the thermoplastic core to sandwich the elements, and cooling the interfaces below the melting point of each of the thermoplastic skin and the thermoplastic core to consolidate the thermoplastic skin and the thermoplastic core into a unitary thermoplastic component. An optional thermoplastic film may be disposed between the thermoplastic skin and the thermoplastic core. The thermoplastic skin may be joined to the thermoplastic core to form an intermediate thermoplastic component prior to joining the thermoplastic skin to the intermediate component.

Abstract: In some embodiments, a pod assembly transportation system includes a transportation services provider computing system and a plurality of flying frame flight control systems, wherein the system is configured to receive, at the transportation services provider computing system, a request for transportation of a pod assembly; upload a flight plan to a flight control system of a flying frame including an airframe and a distributed propulsion system coupled to airframe; dispatch the flying frame by air to the current location of the pod assembly; couple the pod assembly to the flying frame; transport the pod assembly by air from the current location of the pod assembly to the destination of the pod assembly including transitioning the flying frame between a vertical takeoff and landing mode and a forward flight mode; and decouple the pod assembly from the flying frame at the destination of the pod assembly.

Abstract: In some embodiments, a propulsion assembly for an aircraft includes a nacelle, at least one self-contained fuel tank disposed within the nacelle operable to contain a liquid fuel, an engine disposed within the nacelle operable to run on the liquid fuel, a drive system mechanically coupled to the engine and operable to rotate responsive to rotation of the engine, a rotor hub mechanically coupled to the drive system operable to rotate responsive to rotation of the drive system and a proprotor mechanically coupled to the rotor hub and operable to rotate therewith.

Abstract: An aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons coupled therebetween. The airframe has a longitudinal axis and a lateral axis in hover. A two-dimensional distributed thrust array is coupled to the airframe. The thrust array includes a plurality of propulsion assemblies each operable for variable speed and omnidirectional thrust vectoring. A flight control system is operable to independently control the speed and thrust vector of each of the propulsion assemblies such that in an inclined flight attitude with at least one of the longitudinal axis and the lateral axis extending out of a horizontal plane, the flight control system is operable to maintain hover stability responsive to controlling the speed and the thrust vector of the propulsion assemblies.

Abstract: An inertia weight assembly positionable within a receiving portion of a rotor blade for use on a rotorcraft. The inertia weight assembly includes a weighted core and a casing having a closed outboard end and forming a cavity. The weighted core is disposed in the cavity such that the casing at least partially encloses the weighted core. The weighted core is formed from a first material and the casing is formed from a second material that is dissimilar to the first material. The casing provides an interface between the weighted core and the receiving portion of the rotor blade. The second material is more bondable to the receiving portion of the rotor blade than the first material.