Abstract: A molding system and methods of forming a structure are presented. A molding system is configured to form a composite structure. The molding system comprises a first tool comprising a first vacuum groove, a first trough having a first edge configured to form a first bend of the composite structure, and a first molding surface; and a second tool comprising a second vacuum groove, a second trough having a second edge configured to form a second bend of the composite structure, and a second molding surface.

Abstract: A molding system and methods of forming a structure are presented. A molding system is configured to form a composite structure. The molding system comprises a first tool comprising a first vacuum groove, a first trough having a first edge configured to form a first bend of the composite structure, and a first molding surface; and a second tool comprising a second vacuum groove, a second trough having a second edge configured to form a second bend of the composite structure, and a second molding surface.

Abstract: A method of infusing liquid resin into a preform involves positioning a preform on a planar section of a tool surface and a trough section of the tool surface, where the planar section of the tool surface is positioned vertically above the trough section of the tool surface and with there being a plurality of grooves in the planar section of the tool surface and a bottom of the trough section of the tool surface. At least one of a fluid impervious sheet, a second tool and a vacuum bag is secured on the tool surface over the preform forming a sealed volume on the tool surface. A pressure differential and a flow of resin is supplied onto the tool surface and the liquid resin is infused into the preform by the pressure differential.

Abstract: A method for fabricating a hat stiffener which includes a step of positioning two or more reinforcement fiber layers about a mandrel. The method further includes a step of cutting through the two or more reinforcement fiber layers forming a first stack of first end portions of the two or more reinforcement fiber layers and a second stack of second end portions of the two or more reinforcement fiber layers wherein the first and second stacks are in overlying relationship with respect to the mandrel. In addition, the method further includes moving the first stack of the first end portions and the second stack of the second end portions of the two or more reinforcement fiber layers out of overlying relationship with respect to the mandrel.

Abstract: A tool and its method of use, where a plurality of grooves are formed into the tool surface of the tool. The grooves have different cross-section dimensions, different lengths, different configurations and/or different patterns that function as tool surface resin distribution grooves. The grooves distribute and deliver resin supplied to the tool surface throughout a dry fiber composite layup positioned on the tool surface in resin infusion and resin transfer molding. The grooves are formed in the tool surface extending to discrete areas on the tool surface to direct a flow of liquid resin to the discrete areas and infuse the dry fiber composite layup with the liquid resin at those discrete areas of the tool surface.

Abstract: A composite truss structure may have a first facesheet, a second facesheet, and a plurality of truss elements joined with the first facesheet and the second facesheet at nodes to form a one-piece structure. The composite truss structure may be formed by a method comprising preparing a dry fabric mold by: 1) placing a first dry fabric layer on a tool, 2) placing a first layer of fabric-loaded mandrels on the first dry fabric layer, 3) placing a second layer of the fabric-loaded mandrels on the first layer of fabric-loaded mandrels, and 4) placing a second dry fabric layer over the fabric-loaded mandrels. The method may further comprise infusing the dry fabric mold with a resin, and curing the resin to provide the nonflexible composite truss structure.

Abstract: A method for fabricating a hat stiffener which includes a step of positioning two or more reinforcement fiber layers about a mandrel. The method further includes a step of cutting through the two or more reinforcement fiber layers forming a first stack of first end portions of the two or more reinforcement fiber layers and a second stack of second end portions of the two or more reinforcement fiber layers wherein the first and second stacks are in overlying relationship with respect to the mandrel. In addition, the method further includes moving the first stack of the first end portions and the second stack of the second end portions of the two or more reinforcement fiber layers out of overlying relationship with respect to the mandrel.

Abstract: A multifunctional mandrel end cap for the fabrication of composite parts having an end cap core operatively connected to a mandrel and substantially sealed using a bonding agent or end cap sheath. The end cap sheath substantially encloses the end cap core and seals engage perimeter sealing features of the end cap core. The end cap core has a passageway fluidly connecting the mandrel with a vacuum source. The vacuum source is engageable by a vacuum conduit having one or more vacuum conduit perimeter sealing features.

Abstract: A method for assembling a stiffened composite structure includes a step of positioning a plurality of dry fibers along a first side of a pre-preg composite laminate skin element wherein the pre-preg composite laminate skin element is dimensionally changeable. The method further includes a step of positioning an interlayer between the plurality of dry fibers and the first side of the pre-preg composite laminate skin element and a step of infusing the plurality of dry fibers with a resin forming a plurality of infused fibers. The method also includes a step of co-curing the pre-preg composite laminate skin element and the plurality of infused fibers.

Abstract: A method for assembling a stiffened composite structure includes a step of co-bonding a cured infused composite stiffener to a pre-preg composite laminate skin element, wherein the pre-preg composite laminate skin element is dimensionally changeable. Another method for assembling a stiffened composite structure includes a step of coupling a cured infused composite stiffener which includes a preform of a plurality of braided fibers to a pre-preg composite laminate skin element, wherein the pre-preg composite laminate skin element is dimensionally changeable.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts. The method allows for a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish. The component may be placed in direct contact with a tool, and the caul sheet may be placed in direct contact with the component thereby eliminating the necessity for consumables between these items.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Abstract: A multifunctional mandrel end cap for the fabrication of composite parts having an end cap core operatively connected to a mandrel and substantially sealed using a bonding agent or end cap sheath. The end cap sheath substantially encloses the end cap core and seals engage perimeter sealing features of the end cap core. The end cap core has a passageway fluidly connecting the mandrel with a vacuum source. The vacuum source is engageable by a vacuum conduit having one or more vacuum conduit perimeter sealing features.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Abstract: A composite truss structure may have a first facesheet, a second facesheet, and a plurality of truss elements joined with the first facesheet and the second facesheet at nodes to form a one-piece structure. The composite truss structure may be formed by a method comprising preparing a dry fabric mold by: 1) placing a first dry fabric layer on a tool, 2) placing a first layer of fabric-loaded mandrels on the first dry fabric layer, 3) placing a second layer of the fabric-loaded mandrels on the first layer of fabric-loaded mandrels, and 4) placing a second dry fabric layer over the fabric-loaded mandrels. The method may further comprise infusing the dry fabric mold with a resin, and curing the resin to provide the nonflexible composite truss structure.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Abstract: A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure. The stiffener and runout may comprise a crown, side walls, and base cap. The transition in the runout may include a width of the crown increasing, a height of the side walls decreasing, and the base cap splaying outwardly.

Abstract: A composite structure is made by placing a stiffener preform and a composite structure reinforcement on a tool. The preform and the reinforcement are vacuum bagged processed and co-infused with a thermoset resin to form a stiffened, unitized structure.