Abstract: A mold assembly for manufacturing a composite part with a stiffener, the mold assembly includes a bottom mold configured to form a first surface of the composite part, wherein the bottom mold has at least one elongated recess configured to form a stiffener in the composite part; a feeder unit having a shape corresponding to the at least one elongated recess, wherein the feeder unit is configured to fit at least partially into the at least one elongated recess; and a top mold configured to form a second surface of the composite part opposite to the first surface. Also a method of manufacturing a composite part using such a mold assembly, which includes draping a flat laminate over the bottom mold and pushing portions of the laminate into the at least one elongated recess.

Abstract: A method for welding thermoplastic components, in particular, thermoplastic fiber composite structural components for an aircraft or spacecraft, having the following steps. Arranging an insert, which has a conductor structure having a plurality of parallel electrical conductor elements, in a joining zone between a first thermoplastic component and a second thermoplastic component such that at least some portions of the parallel electrical conductor elements are located in the joining zone; locally melting the components in the region of the joining zone by supplying current to the conductor structure; disconnecting the connector elements; and removing the insert from the joining zone by pulling out the disconnected conductor elements. An insert for the resistance welding of thermoplastic components is also provided.

Abstract: A process for producing a polymeric stiffened sheet-like component, for example a panel, for aircraft construction. Production includes integration of hollow stiffening profiles, for example closed omega stringers, onto a sheet-like component, for example an external skin, where the stringers and external skin are produced from thermoplastic composite material. The stringers are integrated onto the external skin by establishing contact between the stringers and the external skin and melting thermoplastic composite material with exposure to heat and pressure at the areas of contact between external skin and stringers. Melting of the other sections of the stringers is avoided with a pressurized cooling fluid with a temperature significantly below the melting point of thermoplastic composite material, the fluid flowing through the airtight enclosed space in the stringers.

Abstract: A mold assembly for manufacturing a composite part with a stiffener, the mold assembly includes a bottom mold configured to form a first surface of the composite part, wherein the bottom mold has at least one elongated recess configured to form a stiffener in the composite part; a feeder unit having a shape corresponding to the at least one elongated recess, wherein the feeder unit is configured to fit at least partially into the at least one elongated recess; and a top mold configured to form a second surface of the composite part opposite to the first surface. Also a method of manufacturing a composite part using such a mold assembly, which includes draping a flat laminate over the bottom mold and pushing portions of the laminate into the at least one elongated recess.

Abstract: A method for welding thermoplastic components, in particular, thermoplastic fiber composite structural components for an aircraft or spacecraft, having the following steps. Arranging an insert, which has a conductor structure having a plurality of parallel electrical conductor elements, in a joining zone between a first thermoplastic component and a second thermoplastic component such that at least some portions of the parallel electrical conductor elements are located in the joining zone; locally melting the components in the region of the joining zone by supplying current to the conductor structure; disconnecting the connector elements; and removing the insert from the joining zone by pulling out the disconnected conductor elements. An insert for the resistance welding of thermoplastic components is also provided.

Abstract: A process for producing a polymeric stiffened sheet-like component, for example a panel, for aircraft construction. Production includes integration of hollow stiffening profiles, for example closed omega stringers, onto a sheet-like component, for example an external skin, where the stringers and external skin are produced from thermoplastic composite material. The stringers are integrated onto the external skin by establishing contact between the stringers and the external skin and melting thermoplastic composite material with exposure to heat and pressure at the areas of contact between external skin and stringers. Melting of the other sections of the stringers is avoided with a pressurized cooling fluid with a temperature significantly below the melting point of thermoplastic composite material, the fluid flowing through the airtight enclosed space in the stringers.

Abstract: A connection adapter for conducting resin into an inner fluid line of a device for vacuum infusion has a bearing side and a connection side, wherein the bearing side has two bearing legs for placing on a fluid line which form an interspace which widens outwardly in a direction facing away from the connection side, and wherein the connection side has a hollow-cylindrical portion with a connection opening facing away from the bearing side, and with a connecting opening projecting into the bearing side, and with a fluid connection between the connection opening and the connecting opening.

Abstract: A tool for use in consolidation of a fibre-reinforced component has an outer casing supported by an internal structure. The outer casing has a first contact surface, which is provided for the purpose of resting flat against the component during the consolidation of the component and predetermining a shape of the component in some section or sections. The internal structure and the outer casing are configured in such a way that, when the tool is heated from an initial temperature to a consolidation temperature required for the consolidation of the component, the tool expands in such a way perpendicularly to the first contact surface that a defined first pressure is exerted on the component by the first contact surface. The use of a component of this kind is furthermore claimed and described.

Abstract: A device for the production of structural components from a fiber composite material, the components being three-dimensionally arched over a large surface, including a jig having a convex mounting surface having receiving channels for the insertion of structural components, wherein the loaded jig interacts with a laminating bonding device having a corresponding shape for forming the structural component under pressure, wherein the mounting surface includes a plurality of individually elastically deformable mounting shell parts arranged adjacent to each other along at least one longitudinally extending pitch line and attached to a plurality of elastically deformable supporting frame elements extending on the interior of the shell at a right angle to the pitch line, and a plurality of actuators for deforming the mounting surface between an extended position (A) and at least one retracted position (B) to move the jig from the bonding device relative to the receiving channels without undercuts.

Abstract: A device and to a method for the production of essentially two-dimensionally arched large-area structural components from a fiber composite material, including a jig having a convex mounting surface which has longitudinally extending receiving channels for the insertion of construction components and which can be loaded with auxiliary materials, wherein the loaded jig interacts with a laminating bonding device having a corresponding shape for forming the structural component under pressure, wherein the jig includes a mounting shell that at the edge can be elastically deformed inwards, which mounting shell, by way of a plurality of actuators that are articulated to the inside, can be moved between an extended position (A) and at least one retracted position (B) in which the jig can be moved relative to the longitudinally extending receiving channels from the laminating bonding device without undercuts.

Abstract: A measurement method for determining the position of an omega profile component placed on a shell component of an aircraft, in which the ACTUAL position of the omega profile component relative to the shell component is optically acquired in a contactless manner, so as to subsequently compare the latter with a defined DESIRED position, wherein several adjacently spaced apart measuring points are established at two mutually opposing flank sides of the profile cross section of the omega profile component, through which a regression line is run according to the path measurement principle based on coordinates, whose point of intersection is drawn upon to determine the orthogonal position of the omega profile component relative to the shell component.

Abstract: A measurement method for determining the position of an omega profile component placed on a shell component of an aircraft, in which the ACTUAL position of the omega profile component relative to the shell component is optically acquired in a contactless manner, so as to subsequently compare the latter with a defined DESIRED position, wherein several adjacently spaced apart measuring points are established at two mutually opposing flank sides of the profile cross section of the omega profile component, through which a regression line is run according to the path measurement principle based on coordinates, whose point of intersection is drawn upon to determine the orthogonal position of the omega profile component relative to the shell component.