Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method of fabricating a composite part. The method includes providing a preform on a tool mandrel, positioning sensors around the preform according to a target shape of the composite part, and sealing the preform with a vacuum bag to form a chamber. The method also includes applying temperature and pressure to the chamber to infuse a resin into the preform to create a composite preform undergoing infusion, monitoring a thickness of the composite preform prior to completing cure, and adjusting at least one of the temperature and the pressure prior to completing cure based on the thickness.

Abstract: A ply for fabricating composite material includes a first tow of a plurality of fibers, which are spread in a direction along a width of a cross section of the ply, wherein a first sheet of enhanced performance material overlies the first tow. A second tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, overlies the first sheet of the enhanced performance material. Another tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, are positioned against and laterally extend from the first tow, the second tow and the first sheet of enhanced performance material.

Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method of fabricating a composite part. The method includes providing a preform on a tool mandrel, positioning sensors around the preform according to a target shape of the composite part, and sealing the preform with a vacuum bag to form a chamber. The method also includes applying temperature and pressure to the chamber to infuse a resin into the preform to create a composite preform undergoing infusion, monitoring a thickness of the composite preform prior to completing cure, and adjusting at least one of the temperature and the pressure prior to completing cure based on the thickness.

Abstract: A ply for fabricating composite material which includes a first tow including a plurality of fibers spread in a direction along a width of a cross section of the ply. A first sheet of enhancement performance material extends within the plurality of fibers and between a top and a bottom of the cross section of the ply.

Abstract: A ply for fabricating composite material includes a first tow of a plurality of fibers, which are spread in a direction along a width of a cross section of the ply, wherein a first sheet of enhanced performance material overlies the first tow. A second tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, overlies the first sheet of the enhanced performance material. Another tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, are positioned against and laterally extend from the first tow, the second tow and the first sheet of enhanced performance material.

Abstract: A method and apparatus for forming a composite structure. The apparatus comprises a fiber layer. The fiber layer comprises a plurality of fiber bundles and a number of filler portions. The plurality of fiber bundles has a number of spaces between the plurality of fiber bundles. A number of filler is comprised of discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles.

Abstract: A method for assembling a stiffened composite structure includes a step of positioning a plurality of dry fibers along a first side of a pre-preg composite laminate skin element wherein the pre-preg composite laminate skin element is dimensionally changeable. The method further includes a step of positioning an interlayer between the plurality of dry fibers and the first side of the pre-preg composite laminate skin element and a step of infusing the plurality of dry fibers with a resin forming a plurality of infused fibers. The method also includes a step of co-curing the pre-preg composite laminate skin element and the plurality of infused fibers.

Abstract: A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Abstract: A ply for fabricating composite material which includes a first tow including a plurality of fibers spread in a direction along a width of a cross section of the ply. A first sheet of enhancement performance material extends within the plurality of fibers and between a top and a bottom of the cross section of the ply.

Abstract: A method and apparatus for forming a composite structure. The apparatus comprises a fiber layer. The fiber layer comprises a plurality of fiber bundles and a number of filler portions. The plurality of fiber bundles has a number of spaces between the plurality of fiber bundles. A number of filler is comprised of discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles.