Abstract: A composite strut includes a first end and first aperture opposite a second end and second aperture separated by a strut distance along a longitudinal axis. A compression block is disposed between the first and the second aperture. A tension strap has a first continuous fiber reinforced plastic composite wrapped repeatedly around the first aperture, along the top side of the compression block, around the second aperture and along the bottom side of the compression block at least two times, wherein fibers of the tension strap are oriented extending parallel to the longitudinal axis between the first and second apertures. An overwind has a second continuous fiber reinforced plastic composite wrapped repeatedly around the first continuous fiber reinforced plastic composite and the compression block between the first end and second end at least two times, wherein fibers of the overwind are oriented extending around the longitudinal axis.

Abstract: A novel composite beam is disclosed. The composite beam may comprise variations in the surface that can be used to create open and closed surfaces for the modulation of natural light. The composite beam may also be optimized for the applied loads by placing the fibers in the direction of the applied loads and/or increasing the fiber density in the regions of higher loads.

Abstract: An improved thermoplastic composite prepreg tape is disclosed. The prepreg tape is optimized for high-speed, high quality in-situ consolidation during automated fiber placement. Embodiments of the prepreg tape have uniform dimensions (cross section, width, and thickness), uniform energy absorption, uniform surface roughness, and sufficient resin at the surface to affect a bond between layers. A scattering agent is used in a polymer surface layer to enable a combination of scattering and absorption in the polymer surface layer.

Abstract: A method for forming a structure having lightning strike protection includes receiving at least one structural layer, receiving at least one lightning strike protection strip disposed on at least one reinforcement layer, automatically applying the at least one lightning strike protection strip disposed on the at least one reinforcement layer onto the at least one structural layer, and forming the at least one structural layer, the at least one lightning strike protection strip, and the at least one reinforcement layer, into the structure. The at least one lightning strike protection strip comprises a first material, and the at least one reinforcement layer comprises a second material different from the first material. The automatically applying may include using at least one of fiber placement equipment, tape laying equipment, and similar automated equipment.

Abstract: A pressure head for use in a fiber placement system for thermoplastic composite materials is disclosed. Plies of thermoplastic composite tape are placed onto a mandrel to form a shaped object. The pressure head includes a nozzle and at least one delivery tube for providing fluid medium mixture to the nozzle body, wherein the nozzle directs the fluid medium onto a surface of the shaped object thereby providing a pressure on the surface without direct physical contact of the nozzle with the plies of thermoplastic composite tape.

Abstract: A novel composite beam is disclosed. The composite beam may comprise variations in the surface that can be used to create open and closed surfaces for the modulation of natural light. The composite beam may also be optimized for the applied loads by placing the fibers in the direction of the applied loads and/or increasing the fiber density in the regions of higher loads.

Abstract: A pressure head for use in a fiber placement system for thermoplastic composite materials is disclosed. Plies of thermoplastic composite tape are placed onto a mandrel to form a shaped object. The pressure head includes a nozzle and at least one delivery tube for providing fluid medium mixture to the nozzle body, wherein the nozzle directs the fluid medium onto a surface of the shaped object thereby providing a pressure on the surface without direct physical contact of the nozzle with the plies of thermoplastic composite tape.

Abstract: A method for forming a structure having lightning strike protection includes receiving at least one structural layer, receiving at least one lightning strike protection strip disposed on at least one reinforcement layer, automatically applying the at least one lightning strike protection strip disposed on the at least one reinforcement layer onto the at least one structural layer, and forming the at least one structural layer, the at least one lightning strike protection strip, and the at least one reinforcement layer, into the structure. The at least one lightning strike protection strip comprises a first material, and the at least one reinforcement layer comprises a second material different from the first material. The automatically applying may include using at least one of fiber placement equipment, tape laying equipment, and similar automated equipment.