Abstract: In some embodiments, an aircraft includes a flying frame having an airframe with first and second wing members having a plurality of pylons extending therebetween, a distributed propulsion system including a plurality of propulsion assemblies securably attached to the airframe and a flight control system operably associated with the distributed propulsion system. The flying frame has a vertical takeoff and landing mode with the wing members disposed in generally the same horizontal plane and a forward flight mode with the wing members disposed in generally the same vertical plane.

Abstract: In some embodiments, an aircraft includes a flying frame having an airframe, a propulsion system attached to the airframe and a flight control system operably associated with the propulsion system wherein, the flying frame has a vertical takeoff and landing mode and a forward flight mode. A pod assembly is selectively attachable to the flying frame such that the flying frame is rotatable about the pod assembly wherein, the pod assembly remains in a generally horizontal attitude during vertical takeoff and landing, forward flight and transitions therebetween.

Abstract: In some embodiment, an aircraft includes an airframe, a propulsion system attached to the airframe and a flight control system operably associated with the propulsion system. A pod assembly is selectively attachable to the flying frame. The flying frame has a vertical takeoff and landing mode and a forward flight mode. The flying frame has a manned flight mode and an unmanned flight mode.

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: In some embodiments, a passenger 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 passenger pod assembly having a current location and a destination; upload a flight plan to a flight control system of a flying frame including an airframe and a propulsion system; dispatch the flying frame to the current location of the passenger pod assembly; couple the flying frame to the passenger pod assembly at the current location of the passenger pod assembly; transport the passenger pod assembly by air from the current location of the passenger pod assembly to the destination of the passenger pod assembly; and decouple the passenger pod assembly from the flying frame at the destination of the passenger pod assembly.

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: A tiltrotor aircraft includes a fuselage, a wing member extending from the fuselage, an engine disposed relative to the wing member and a proprotor mechanically coupled to the engine. The proprotor includes a plurality of proprotor blade assemblies each including a spar and a sheath extending spanwise along the spar forming the leading edge of the proprotor blade assembly. The spar has a root section, a main section and a tip section. The spar has a generally oval cross section at radial stations along the main section and a first edge having a structural bias relative to a generally oppositely disposed second edge at the radial stations along the main section.

Abstract: A tiltrotor aircraft includes a fuselage, a wing member extending from the fuselage, an engine disposed relative to the wing member, a rotor hub assembly mechanically coupled to the engine and a plurality of proprotor blade assemblies rotatably mounted to the rotor hub assembly and operable for beamwise folding relative thereto. The proprotor blade assemblies each including a spar and a sheath extending spanwise along a leading edge of the spar. The spar has a root section, a main section and a tip section. The spar has a generally oval cross section at radial stations along the main section of the spar with the root section of the spar forming an integral tang assembly operable for coupling the spar to the rotor hub assembly.

Abstract: One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: One aspect of a process of forming an aircraft component includes bonding a first end of a honeycomb structure to a surface of an aircraft skin member, the honeycomb structure including multiple connected cells. Foam is sprayed on a second end of the honeycomb structure opposite the first end. The process also includes curing the foam on the second end of the honeycomb structure.

Abstract: In one aspect, there is a rib assembly for an aircraft wing including a rib web having a top and a bottom, the rib web includes a first laminate, a second laminate, and a honeycomb panel having an array of large cells disposed between the first laminate and the second laminate, each cell having a width of at least 1 cm; and a plurality of skin flanges for fixedly attaching the rib web to a skin of the wing, each skin flange has a base member having a first portion and a second portion and a vertical member extending from the base member. The plurality of skin flanges can be attached to the top and the bottom of the rib web such that the second portion of the base member and the vertical member are attached to the rib web.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

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: A structural joint includes a first member having a first base portion and a first leg portion. The structural joint further includes a second member having a second base portion and a second base portion. The first base portion and the second base portion are coupled together at an overlapping portion. The first leg portion and the second leg portion form a cavity for structurally coupling to a structural member.

Abstract: A rotorcraft rotor blade assembly includes an upper skin portion extending substantially a full span of the rotor blade assembly and a lower skin portion extending substantially the full span of the rotor blade assembly. Each of the upper skin portion and the lower skin portion is configured to carry at least substantially 30% of rotor blade assembly loads.

Abstract: A method of manufacturing a core stiffened structure includes orienting the plurality of core wafers in a non-uniform pattern onto a first face sheet, the non-uniform pattern producing non-uniform spacing between adjacent core wafers; assembling a second face sheet onto the plurality of wafers; and curing an adhesive to create a bond between the plurality of wafers, the first face sheet, and the second face sheet.

Abstract: A rotorcraft rotor blade assembly includes a stub spar extending less than a full span of the rotor blade assembly. An upper skin portion extends substantially the full span of the rotor blade assembly. A lower skin portion extends substantially the full span of the rotor blade assembly. The stub spar is positioned between the upper skin portion and the lower skin portion.

Abstract: A method of manufacturing a composite core can include: wrapping a mandrel in a mandrel wrapping process by securing a mandrel with a winding jig; orienting the composite material at a wrap angle to the mandrel; and depositing the composite material around a circumference of the mandrel. The method can further include assembling the wrapped mandrels in a tool and applying a pressure to the composite material during a curing cycle.