Abstract: Disclosed is a method of forming a composite door. A precursor frame sheet, comprising flaps, is formed by cutting a prepreg sheet. The precursor frame sheet is draped over a door-forming tool, comprising a frame face and flap supports, non-parallel to the frame face, such that each of the flaps of the precursor frame sheet is geometrically complementary with a corresponding one of the flap supports. A composite frame is formed by curing the precursor frame sheet, draped over the door-forming tool, wherein the composite frame comprises a first rail and a second rail. The composite frame is separated from the door-forming tool. The composite frame, first composite edge fittings, second composite edge fittings, a first composite side beam, a second composite side beam, and a composite skin are interconnected.

Abstract: A composite door comprises a composite frame, which comprises a first rail, a second rail, and crossbeams, joining the first rail and the second rail. The composite door also comprises a first composite side beam, a second composite side beam, and a composite skin, connected to each of the crossbeams of the composite frame, to the first composite side beam, and to the second composite side beam. The composite door further comprises first composite edge fittings, each connected to a corresponding one of the crossbeams of the composite frame, to the first composite side beam, and to the composite skin, and second composite edge fittings, each connected to a corresponding one of the crossbeams of the composite frame, to the second composite side beam, and to the composite skin.

Abstract: A composite door comprises a composite frame, which comprises a first rail, a second rail, and crossbeams, joining the first rail and the second rail. The composite door also comprises a first composite side beam, a second composite side beam, and a composite skin, connected to each of the crossbeams of the composite frame, to the first composite side beam, and to the second composite side beam. The composite door further comprises first composite edge fittings, each connected to a corresponding one of the crossbeams of the composite frame, to the first composite side beam, and to the composite skin, and second composite edge fittings, each connected to a corresponding one of the crossbeams of the composite frame, to the second composite side beam, and to the composite skin.

Abstract: An aircraft flap is constructed of nested layers of composite material in the aircraft flap that include an inner layer, a middle layer and an outer layer. The aircraft flap is constructed with the inner layer laid up around a central mandrel, the middle layer laid up around the middle layer and the outer layer laid up around the middle layer. The inner layer, the middle layer and the outer layer are co-cured on the mandrel, removed from the mandrel and then assembled together with the inner layer formed in a folded over configuration around a hollow interior volume of the aircraft flap, the middle layer formed in a folded over configuration over the inner layer, and the outer layer formed in a folded over configuration around the middle layer.

Abstract: An aircraft flap is constructed of nested layers of composite material in the aircraft flap that include an inner layer, a middle layer and an outer layer. The aircraft flap is constructed with the inner layer laid up around a central mandrel, the middle layer laid up around the middle layer and the outer layer laid up around the middle layer. The inner layer, the middle layer and the outer layer are co-cured on the mandrel, removed from the mandrel and then assembled together with the inner layer formed in a folded over configuration around a hollow interior volume of the aircraft flap, the middle layer formed in a folded over configuration over the inner layer, and the outer layer formed in a folded over configuration around the middle layer.