Abstract: Ceramic matrix composite articles include, for example a first plurality of plies of ceramic fibers in a ceramic matrix defining a first extent, and a local at least one second ply in said ceramic matrix defining a second extent on and/or in said first plurality of plies with the second extent being less than said first extent. The first plurality of plies has a first property, the at least one second ply has at least one second property, and said first property being different from said at least one second property. The different properties may include one or more different mechanical (stress/strain) properties, one or more different thermal conductivity properties, one or more different electrical conductivity properties, one or more different other properties, and combinations thereof.

Abstract: Ceramic matrix composite articles include, for example a first plurality of plies of ceramic fibers in a ceramic matrix defining a first extent, and a local at least one second ply in said ceramic matrix defining a second extent on and/or in said first plurality of plies with the second extent being less than said first extent. The first plurality of plies has a first property, the at least one second ply has at least one second property, and said first property being different from said at least one second property. The different properties may include one or more different mechanical (stress/strain) properties, one or more different thermal conductivity properties, one or more different electrical conductivity properties, one or more different other properties, and combinations thereof.

Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.

Abstract: A device for the placement of material on a surface includes a housing, a motor coupled to the housing, and a driving component coupled to the housing and powered by the motor. The device further includes at least one guide chute defining a guide channel with the driving component. The device further includes a layup roller coupled to the housing adjacent the guide channel. The layup roller includes a roller surface and the guide channel is configured to discharge a quantity of material to the roller surface. The layup roller is configured to deposit the material onto the surface.

Abstract: An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.

Abstract: A system for forming material includes a housing including at least one wall defining an interior space. The housing is configured to contain a pressurized fluid in the interior space. The system also includes at least one tool configured to shape the material. The at least one tool is movable along a path from a first position external to the housing to a second position at least partially within the interior space. The system further includes a membrane extending at least partially in the path of the at least one tool.

Abstract: Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

Abstract: A film separation system for use in separating a removable film adhered to a ply of material positioned on a work surface. The film separation system includes a holding member configured to hold the ply of material on the work surface, a movable arm configured to translate relative to the work surface, and a rotatable brush coupled to the movable arm. The movable arm is configured to translate the rotatable brush towards an edge of the ply of material, and the rotatable brush is oriented relative to the ply of material such that, when rotated, the rotatable brush is configured to bias the removable film away from the work surface, thereby creating a region of separation between the ply and the removable film.

Abstract: A method of molding a composite structure having continuous fibers contained therein is disclosed. The method including the steps of compressing a first composite material in a mold; forming a cavity in the first composite material; placing a second composite material having continuous fibers contained therein in the cavity formed in the first composite material to minimize movement and distortion of the continuous fibers; compressing the first composite material such that the compression of the first composite material causes the first composite material to flow to edges of the second composite material; and allowing the first composite material to bond to the second composite material under molding temperature and pressure to form the composite structure.

Abstract: A system includes a gripper device to grasp a disposable proxy. The gripper device is moveable to position a pressure sensitive adhesive in contact with the disposable proxy and apply a pressure force to adhere the pressure sensitive adhesive to the disposable proxy. The gripper device is moveable to position the pressure sensitive adhesive in contact with an edge portion of a first layer of a plurality of layers and apply a pressure force to adhere the pressure sensitive adhesive to the edge portion of the first layer. The system further includes a cutting device moveable to apply a cutting force to separate a sacrificial corner portion of the first layer proximate the edge portion of the first layer from a remaining portion of the first layer. The gripper device is movable to peel the remaining portion of the first layer from one or more remaining layers of the plurality of layers.

Abstract: An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.

Abstract: A method of molding a composite structure having continuous fibers contained therein is disclosed. The method including the steps of compressing a first composite material in a mold; forming a cavity in the first composite material; placing a second composite material having continuous fibers contained therein in the cavity formed in the first composite material to minimize movement and distortion of the continuous fibers; compressing the first composite material such that the compression of the first composite material causes the first composite material to flow to edges of the second composite material; and allowing the first composite material to bond to the second composite material under molding temperature and pressure to form the composite structure.

Abstract: Ceramic matrix composite articles include, for example a first plurality of plies of ceramic fibers in a ceramic matrix defining a first extent, and a local at least one second ply in said ceramic matrix defining a second extent on and/or in said first plurality of plies with the second extent being less than said first extent. The first plurality of plies has a first property, the at least one second ply has at least one second property, and said first property being different from said at least one second property. The different properties may include one or more different mechanical (stress/strain) properties, one or more different thermal conductivity properties, one or more different electrical conductivity properties, one or more different other properties, and combinations thereof.

Abstract: A system for forming material includes a housing including at least one wall defining an interior space. The housing is configured to contain a pressurized fluid in the interior space. The system also includes at least one tool configured to shape the material. The at least one tool is movable along a path from a first position external to the housing to a second position at least partially within the interior space. The system further includes a membrane extending at least partially in the path of the at least one tool.

Abstract: A device for the placement of material on a surface includes a housing, a motor coupled to the housing, and a driving component coupled to the housing and powered by the motor. The device further includes at least one guide chute defining a guide channel with the driving component. The device further includes a layup roller coupled to the housing adjacent the guide channel. The layup roller includes a roller surface and the guide channel is configured to discharge a quantity of material to the roller surface. The layup roller is configured to deposit the material onto the surface.

Abstract: A rotor blade assembly including a first blade section including a joint end and a custom fit second blade section including a joint end, and a method of fabricating the rotor blade assembly is disclosed. One of the first blade section or the custom fit second blade section includes an inner surface defining a cavity. The cavity is configured to receive the joint end of the other one of the blade sections in an overlapping configuration to define an overlapping region and a mating joint. A joining means is used to secure the joint ends of the blade sections. A profile of the outer surface of the custom fit second blade section generally corresponds to the aerodynamic profile of the first blade section such that a substantially continuous aerodynamic profile is defined between the blade sections when the joint ends are configured in the overlapping configuration.

Abstract: A composite article including a composite component, a metallic component and one or more interlock components. The composite component including a plurality of composite plies and extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges, the composite. The metallic component including a first surface and a second surface and a plurality of openings formed therein extending from the first surface to the second surface. The metallic component including at least a portion substantially or fully embedded in the composite component. The one or more interlock components is interwoven through one or more of the plurality of openings in the metallic component and extending into and at least partially embedded in the composite component to provide an interlocking system between the composite component and the metallic component. A method of fabrication of a composite article is also provided.