Abstract: A method for the manufacturing of three-dimensional (3D) preforms and composite structures having non-planar surfaces and flanges such that the fibrous or composite material used for shaping the final 3D structure has the necessary length and surface area to conform to the desired contours of the molding tool without wrinkling. The manufacturing method begins with the formation of an intermediate preform blank by automated placement of fiber tapes or prepreg tapes, followed by shaping the blank on a molding tool with 3D contours to form the final 3D structure.

Abstract: A method for producing a three-dimensional preform from an intermediate preform blank (30, 70), which contain undulations (31) in a portion thereof. The preform blank (30, 79) may be formed on a tool surface (60) containing undulations (61) using an automated placement method such as Automated Tape Laying (ATL) or Automated Fiber Placement (AFP), in which narrow-width strips of material are dispensed side-by-side. Various preform blanks (30, 70) and molding tools (10, 50, 80) have been designed to produce shaped preforms having generally C-shape and Z-shape cross-sections.

Abstract: A method for the manufacturing of three-dimensional (3D) preforms and composite structures having non-planar surfaces and flanges such that the fibrous or composite material used for shaping the final 3D structure has the necessary length and surface area to conform to the desired contours of the molding tool without wrinkling. The manufacturing method begins with the formation of an intermediate preform blank by automated placement of fiber tapes or prepreg tapes, followed by shaping the blank on a molding tool with 3D contours to form the final 3D structure.