Abstract: A composite assembly with a laminate of fibre plies impregnated with a laminate matrix material is disclosed having pad of fibre plies impregnated with a pad matrix material, and a part with a body with protrusions which extend from the body and penetrate at least some of the fibre plies of the pad. The pad is bonded to the laminate by a stepped lap joint or a scarf joint. The assembly is manufactured by pressing the protrusions into the pad, and after the protrusions have been pressed into the pad, curing a pad matrix material impregnating the pad, and bonding the pad to the laminate.

Abstract: A first aspect of the invention provides a method of joining a part to a composite component, the composite component comprising fibres impregnated with a matrix material, and the part comprising a plurality of projections, the method comprising: inserting the projections into the composite component; and pre-heating the projections before they are inserted into the composite component, so that the projections are at a higher temperature than the composite component as they are inserted into the composite component. The projections locally heat the matrix material of the composite component as they are pushed into the composite component. Increased temperature during insertion is advantageous as the reduced matrix viscosity, due to the increased temperature of the matrix, results in better consolidation of the fibres around the projections and minimises the distortion of the fibres.

Abstract: A method of evaluating build orientations for additively manufacturing an object. Multiple data sets are generated from geometry information indicating a geometry of the object. Each data set indicates variation of a respective associated performance indicator over a design space containing multiple possible build orientations. A composite data set is generated by combining the multiple data sets, along with a representation of the composite data set. The representation of the composite data set graphically illustrates variation of the composite data set over the design space. An image is displaying containing the representation of the composite data set. A user input either selects a set of one or more of the possible build orientations or accepts a pre-selected set of one or more of the possible build orientations. A solution is output based on the user input.

Abstract: A composite assembly with a laminate of fibre plies impregnated with a laminate matrix material is disclosed having pad of fibre plies impregnated with a pad matrix material, and a part with a body with protrusions which extend from the body and penetrate at least some of the fibre plies of the pad. The pad is bonded to the laminate by a stepped lap joint or a scarf joint. The assembly is manufactured by pressing the protrusions into the pad, and after the protrusions have been pressed into the pad, curing a pad matrix material impregnating the pad, and bonding the pad to the laminate.

Abstract: A method of joining a first component to a second component. A membrane is provided between the first component and a fluid. Pressure of the fluid is used to apply a compression force to a first part of the first component via the membrane. The pressure of the fluid is also used to apply an insertion force to the second component which pushes projections of the second component into a second part of the first component. The method can be integrated into a conventional manufacturing method, such as a “vacuum-bagging” process, which employs fluid pressure and a non-permeable membrane to compress the first component. The pressure of the fluid is used not only to apply the compression force, but also to apply the insertion force to the second component.

Abstract: A first aspect of the invention provides a method of joining a part to a composite component, the composite component comprising fibres impregnated with a matrix material, and the part comprising a plurality of projections, the method comprising: inserting the projections into the composite component; and pre-heating the projections before they are inserted into the composite component, so that the projections are at a higher temperature than the composite component as they are inserted into the composite component. The projections locally heat the matrix material of the composite component as they are pushed into the composite component. Increased temperature during insertion is advantageous as the reduced matrix viscosity, due to the increased temperature of the matrix, results in better consolidation of the fibres around the projections and minimises the distortion of the fibres.