Abstract: A method for forming a composite sandwich structure by compression molding is disclosed. The method includes: placing a stack of two composite skins (13a, 13b) separated by a non-adherent layer (13c) in a compression molding tool (10); compression molding the stack of composite skins and non-adherent layer while applying heat to the tool, wherein compression molding of the stack is carried out until each composite skin conforms to and adhere to the molding surface adjacent to it but the thermoset resin in each composite skin is not fully cure; opening the compression molding tool, wherein each composite skin remains adhered to the adjacent molding surface; removing the non-adherent layer from the compression molding tool; placing a core layer (14) in the compression molding tool; and compression molding until the core layer is bonded to the composite skins, thereby forming a shaped sandwich structure (15).

Abstract: A hot drape-forming method for shaping fibrous preforms and prepreg plies into complex geometries. For shaping fibrous preforms, the hot drape-forming method includes: a) dividing the total number of preforms into a plurality of sub-preforms (S1, S2, S3); and b) consecutively shaping each sub-preform (S1, S2, S3) by applying vacuum pressure and heat, wherein the shaping of all sub-preforms (S1, S2, S3) are carried out in the same tool housing (10) over the same molding surface. The resulting shaped preform (S1, S2, S3) is ready for resin infusion. The same method can also be used to shape resin-impregnated prepreg plies.

Abstract: A hot drape-forming method for shaping fibrous preforms and prepreg plies into complex geometries. For shaping fibrous preforms, the hot drape-forming method includes: a) dividing the total number of preforms into a plurality of sub-preforms (S1, S2, S3); and b) consecutively shaping each sub-preform (S1, S2, S3) by applying vacuum pressure and heat, wherein the shaping of all sub-preforms (S1, S2, S3) are carried out in the same tool housing (10) over the same molding surface. The resulting shaped preform (S1, S2, S3) is ready for resin infusion. The same method can also be used to shape resin-impregnated prepreg plies.