Abstract: A mold for molding a composite preform that has an outer edge thereabout and a plurality of tethers each attached at respective opposed ends thereof to the outer edge. The mold includes first and second mold halves defining a mold body and being configured to transition between an open position and a generally closed position, and a plurality of moveable members each having a moveable gage pin configured for being wrapped thereabout by a respective one of the tethers and a respective actuator configured for moving the moveable gage pin between a respective first position in which the respective moveable gage pin is disposed at a respective first distance from a center of the mold body and a respective second position in which the respective moveable gage pin is disposed at a respective second distance from the center of the mold body that is less than the first distance.

Abstract: A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

Abstract: A mold for molding a reinforced preform having at least two apertures therein includes first and second mold halves, first and second emitters disposed in the mold halves and configured to emit light therefrom, first and second receivers disposed in the mold halves and configured to receive light from the respective first and second emitters, and first and second moving members having couplings for connection with side portions of the reinforced preform and actuators for moving the couplings between respective first and second positions. A controller determines an alignment condition based on signals received from the receivers. If the alignment condition fails to meet predetermined criteria, then at least one of the actuators is caused to move its coupling from its respective first position to a respective adjusted position that is different from the respective second position.

Abstract: Class-A components (CAC) include a first and second skin layer each having a polymer matrix and a fiber reinforcing material embedded within the polymer matrix, a third layer disposed between the first and second skin layers and including a third polymer matrix and a filler material interspersed within the third polymer matrix, and a Class-A finish coat applied to the second skin layer. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers and a plurality of low strength regions staggered throughout the carbon fibers. The CAC can be integrated with a rigid vehicle frame. The CAC can be a structural component. The CAC can be a door, a roof panel, or a hood. The CAC can include a layer of woven fibers between the Class-A finish coat and the second skin layer and a portion of the woven fibers can be visible through the Class-A surface layer.

Abstract: Methods for fabricating Class-A components (CAC) include providing a molding precursor which includes a first and second skin layer each including a fiber reinforcing material embedded in a polymer matrix, a third layer between the first and second skin layers and including a third polymer matrix and a filler material interspersed therein. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers having a plurality of low strength regions staggered with respect to the second axis. The method includes disposing a molding precursor within a die, compression molding the molding precursor in the die, wherein the die includes a punch configured to contact the second skin layer, opening the die to create a gap between the punch and an outer surface of the second skin layer, and injecting a Class-A finish coat precursor into the gap to create a class-A surface layer and form the CAC.

Abstract: A polymeric sandwich structure having enhanced thermal conductivity includes a first layer formed from a first polymer matrix and including a first fiber reinforcing sheet embedded within the first polymer matrix, a second layer formed from a second polymer matrix and including a second fiber reinforcing sheet embedded within the second polymer matrix, and a third layer disposed between the first and second layers, the third layer formed from a third polymer matrix having graphene nanoplatelets interspersed therein. Each of the first and second fiber reinforcing sheets is made of reinforcing fibers and includes a respective set of staggered discontinuous perforations formed therein, wherein each respective set of staggered discontinuous perforations defines a respective first plurality of reinforcing fibers having a respective first length and a respective second plurality of reinforcing fibers having a respective second length longer than the respective first length.

Abstract: A reinforced preform includes a sheet of reinforced material having opposed first and second edges, with each edge having a respective first connection point located therealong. The preform also includes first and second tethers, with each tether being attached at a respective first end thereof to a respective one of the first connection points and having a respective second end thereof terminating in at least one of: a respective loop tied at the respective second end, a respective knot tied at the respective second end, a respective graspable member to which the respective second end is connected, and an attachment to a respective second connection point located along a perimeter of the sheet. A method and mold for molding a reinforced preform are also disclosed.

Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

Abstract: Class-A components (CAC) include a first and second skin layer each having a polymer matrix and a fiber reinforcing material embedded within the polymer matrix, a third layer disposed between the first and second skin layers and including a third polymer matrix and a filler material interspersed within the third polymer matrix, and a Class-A finish coat applied to the second skin layer. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers and a plurality of low strength regions staggered throughout the carbon fibers. The CAC can be integrated with a rigid vehicle frame. The CAC can be a structural component. The CAC can be a door, a roof panel, or a hood. The CAC can include a layer of woven fibers between the Class-A finish coat and the second skin layer and a portion of the woven fibers can be visible through the Class-A surface layer.

Abstract: Methods for fabricating Class-A components (CAC) include providing a molding precursor which includes a first and second skin layer each including a fiber reinforcing material embedded in a polymer matrix, a third layer between the first and second skin layers and including a third polymer matrix and a filler material interspersed therein. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers having a plurality of low strength regions staggered with respect to the second axis. The method includes disposing a molding precursor within a die, compression molding the molding precursor in the die, wherein the die includes a punch configured to contact the second skin layer, opening the die to create a gap between the punch and an outer surface of the second skin layer, and injecting a Class-A finish coat precursor into the gap to create a class-A surface layer and form the CAC.

Abstract: A method of manufacturing an energy-absorbing structure according to various aspects of the present disclosure via a two-step molding process includes molding first and second portion precursors including thermoset polymers (e.g., thermoset polymer composites) to a first degree of cure (DOC) less than one so that the portion precursors are in a gelled glass state. The method further includes joining the first and second portion precursors by applying heat and pressure in a joining region such that the thermoset polymers have a second DOC greater than the first DOC and are cross-linked in the joining region. The energy-absorbing component therefore has a unitary structure. The method may further include coupling the energy-absorbing structure to a housing. In certain aspects, energy-absorbing structures may have tailored stiffness and/or tailored crush initiation.

Abstract: An assembly for a vehicle having reduced galvanic corrosion includes a first component defining at least one interface region that includes a carbon-fiber reinforced polymeric composite (CFRP) and a first material present in the at least one interface region and having a first electrochemical potential. A second component has a second material and is in contact with the at least one interface region of the first component. The second material has a second electrochemical potential different than the first electrochemical potential. In this manner, in the presence of an electrolyte the first material may be either less noble than the second material and serve as a sacrificial material or alternatively more noble to the second material reducing a driving force for corrosion. Methods of reducing galvanic corrosion in an assembly (e.g., for a vehicle) are also provided.

Abstract: A mold for molding a reinforced preform having at least two apertures therein includes first and second mold halves arranged with their respective first and second molding surfaces facing each other. A first emitter is disposed in the first mold half and is configured to emit light therefrom. A first receiver is disposed in the second mold half and is configured to receive light from the first emitter and produce a first signal indicative of the light received from the first emitter. A second emitter is disposed in one of the first and second mold halves and is configured to emit light therefrom. A second receiver is disposed in the other of the first and second mold halves and is configured to receive light from the second emitter and produce a second signal indicative of the light received from the second emitter.

Abstract: A reinforced preform includes a sheet of reinforced material having opposed first and second edges, with each edge having a respective first connection point located therealong. The preform also includes first and second tethers, with each tether being attached at a respective first end thereof to a respective one of the first connection points and having a respective second end thereof terminating in at least one of: a respective loop tied at the respective second end, a respective knot tied at the respective second end, a respective graspable member to which the respective second end is connected, and an attachment to a respective second connection point located along a perimeter of the sheet. A method and mold for molding a reinforced preform are also disclosed.

Abstract: An apparatus for perforating a carbon fiber substrate material comprises a support structure including a first side support and a second side support and a cylindrical anvil rotatably connected between the first side support and the second side support. The anvil is configured to move the carbon fiber substrate material in response to rotation of the anvil. The apparatus further comprises a cylindrical cutting wheel rotatably connected to the support structure between the first side support and the second side support and positioned adjacent to the anvil. The cutting wheel includes a plurality of blades projecting outward from an outer surface of the cutting wheel wherein the blades of the cutting wheel are configured to perforate the carbon fiber substrate material when the carbon fiber substrate material moves between the anvil and the cutting wheel.

Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: Methods of producing a continuous carbon fiber for use in composites having enhanced moldability are provided. A continuous precursor fiber is formed that has a sheath and a core. The sheath includes a first polymer material. The core includes a second polymer material and a plurality of discrete regions distributed within the second polymer material. The discrete regions include a third polymer material. After the continuous precursor fiber is heated for carbonization and graphitization, the continuous precursor fiber forms a continuous carbon fiber having a plurality of discrete weak regions corresponding to the plurality of discrete regions in the core. Carbon fiber composites made from such modified continuous carbon fibers having enhanced moldability are also provided.

Abstract: Methods of repairing a defect in a polymeric composite structure are provided. The methods include disposing a patch over a defect in a polymeric composite structure; disposing a textured sheet over the polymeric patch, applying pressure to the polymeric patch and the textured sheet; and heating the polymeric patch. The textured sheet has a surface texture that is a negative of a surface texture of the polymeric composite structure.

Abstract: In various aspects, the present disclosure provides a structural component. The structural component includes a body defining at least one hollow region. The body includes a carbon fiber composite including a plurality of substantially aligned continuous carbon fibers. The plurality of substantially aligned carbon fibers defines a major axis and a second axis perpendicular to the major axis. The plurality of substantially aligned continuous carbon fibers includes a plurality of discrete termination points staggered with respect to the second axis. Methods of making such structural components, including by blow molding and compression molding are also provided.