Abstract: A braiding apparatus for forming braided tubing comprises a braiding wheel and a plurality of bobbins. The plurality of bobbins are configured to move circumferentially around the braiding wheel. Each bobbin includes a spool, a first pulley assembly, and a second pulley assembly. The spool is configured to hold a tow formed from a braiding material. The first pulley assembly is coupled to the spool at a first distance from the spool. The first pulley assembly is configured to facilitate passing the tow over a pulley of the first pulley assembly. The second pulley assembly is coupled to the spool at a second distance that is less than the first distance. The second pulley assembly is configured to facilitate receiving the tow from the first pulley assembly and passing the tow over a pulley of the second pulley assembly and towards a section of the braiding apparatus at which a plurality of tows come together to form the braided tubing.

Abstract: A braiding apparatus for forming braided tubing comprises a braiding wheel and a plurality of bobbins. The plurality of bobbins are configured to move circumferentially around the braiding wheel. Each bobbin includes a spool, a first pulley assembly, and a second pulley assembly. The spool is configured to hold a tow formed from a braiding material. The first pulley assembly is coupled to the spool at a first distance from the spool. The first pulley assembly is configured to facilitate passing the tow over a pulley of the first pulley assembly. The second pulley assembly is coupled to the spool at a second distance that is less than the first distance. The second pulley assembly is configured to facilitate receiving the tow from the first pulley assembly and passing the tow over a pulley of the second pulley assembly and towards a section of the braiding apparatus at which a plurality of tows come together to form the braided tubing.

Abstract: A fabrication method of forming a thermoplastic composite laminate material with tailored and varying thickness in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from these multiple ply stacks.

Abstract: A fabrication method of forming a thermoplastic composite laminate material with tailored and varying thickness in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from these multiple ply stacks.

Abstract: Thermoplastic composite laminate parts with tailored and varying thickness and/or curved sections are manufactured in a continuous process. Automated equipment or hand lay-up is used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Some or all of the plies may be continuously fed from spools of single or multiply ply material. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.