Abstract: A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

Abstract: A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

Abstract: A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.

Abstract: A rotor blade for an aircraft includes a composite portion having fiber-reinforced resin material, the composite portion having an outside surface that forms at least a partial airfoil shape. The weighted portion includes a plurality of weighted material layers and a plurality of fiber-reinforced resin material layers. Weighted material is configured to be compatible with and integrated into composite manufacturing processes used to fabricate the rotor blade. The weighted portion has a higher density than the composite portion and positioned to produce desired mass balance characteristics of the rotor blade.

Abstract: A composite assembly has an outer spar component having an outer spar component inner profile, an inner spar component having an inner spar component outer profile substantially complementary to the outer spar component inner profile, and an adhesive disposed between the outer spar component and the inner spar component.

Abstract: An apparatus comprising a soft in plane rotor yoke comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material having a plurality of first fibers oriented in a first direction, and a plurality of second layers formed of a second composite fabric material having a plurality of second fibers oriented in a second direction. Included is an apparatus comprising a soft in plane rotor comprising two longitudinal side portions connected together via two outboard portions, wherein the outboard portions comprise a plurality of first layers formed of a first composite fabric material, and a plurality of second layers formed of a second composite fabric material, wherein the soft in plane rotor yoke does not comprise any narrow steered slit tape or filament windings.

Abstract: A rotor blade for an aircraft includes a composite portion having fiber-reinforced resin material, the composite portion having an outside surface that forms at least a partial airfoil shape. The weighted portion includes a plurality of weighted material layers and a plurality of fiber-reinforced resin material layers. Weighted material is configured to be compatible with and integrated into composite manufacturing processes used to fabricate the rotor blade. The weighted portion has a higher density than the composite portion and positioned to produce desired mass balance characteristics of the rotor blade.

Abstract: An uncured, composite rope includes at least one inner tow of structural fibers of a first material and a plurality of outer tows of structural fibers disposed about the at least one inner tow, the structural fibers of at least one of the plurality of outer tows being made from a second material that is different from the first material. The uncured, composite rope further includes an uncured polymeric resin impregnated into the at least one inner tow and the plurality of outer tows.

Abstract: A resin-impregnated, structural fiber rope includes a plurality of tows disposed in a bundle, each of the plurality of tows including a plurality of structural fibers, and uncured polymeric resin impregnated into the bundle. Each of the plurality of structural fibers defines an angle with respect to a central axis of the rope of no more than about 10 degrees.

Abstract: A resin-impregnated, structural fiber rope includes a plurality of tows disposed in a bundle, each of the plurality of tows including a plurality of structural fibers, and uncured polymeric resin impregnated into the bundle. Each of the plurality of structural fibers defines an angle with respect to a central axis of the rope of no more than about 10 degrees.

Abstract: An uncured, composite rope includes at least one inner tow of structural fibers of a first material and a plurality of outer tows of structural fibers disposed about the at least one inner tow, the structural fibers of at least one of the plurality of outer tows being made from a second material that is different from the first material. The uncured, composite rope further includes an uncured polymeric resin impregnated into the at least one inner tow and the plurality of outer tows.

Abstract: A complex object, such as a spar for a tilt-rotor aircraft rotor blade, is manufactured from fiber composite materials. Unbroken fiber strips are laid along the length of the spar to maximize the number of full length fibers used in the spar. Cross-sectional areas along the length of the spar can change in both shape and area. The fibers are laid to accommodate and form these variable shapes. The locations for the fibers are determined by defining locations for the strips for each cross-section, then connecting corresponding points together to specify where the strips are to be laid down.