Abstract: A component is provided that includes a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer. The thermoplastic layer includes a plurality of reinforcement particles within a thermoplastic matrix. The thermoset layer is configured from or otherwise includes a thermoset matrix.

Abstract: A component is provided that includes a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer. The thermoplastic layer includes a plurality of reinforcement particles within a thermoplastic matrix. The thermoset layer is configured from or otherwise includes a thermoset matrix.

Abstract: A thermoforming method includes heating a thermoplastic panel to a forming temperature, and compressing the thermoplastic panel between a first tool and a second tool, wherein the thermoplastic panel is bent about a first axis extending along a first direction with respect to the thermoplastic panel in response to being compressed between the first tool and the second tool. The thermoplastic panel may then be cooled to a hardened temperature and disposed between a third tool and a fourth tool. The method further includes heating the thermoplastic panel to the forming temperature, and compressing the thermoplastic panel between the third tool and the fourth tool, wherein the thermoplastic panel is bent about a second axis extending along a second direction with respect to the thermoplastic panel in response to being compressed between the third tool and the fourth tool.

Abstract: An acoustic panel includes a first skin, a second skin and a cellular core vertically between and connected to the first skin and the second skin. The cellular core includes a plurality of cavities, a plurality of sidewalls and a plurality of septums. Each of the plurality of cavities extends vertically through the cellular core between the first skin and the second skin. Each of the plurality of cavities extends laterally within the cellular core between a respective laterally adjacent pair of the plurality of sidewalls. Each of the plurality of septums vertically divides a respective one of the plurality of cavities into a set of fluidly coupled sub-cavities. A set of the plurality of septums is formed by a ply of folded material. Each of the set of the plurality of septums have a four-sided polygonal shape when viewed in a plane that is parallel to the first skin.

Abstract: A system for forming a thermoplastic may comprise a mandrel configured to receive a thermoplastic charge. The mandrel may rotate about a mandrel axis. A series of rollers may be located circumferentially about the mandrel and configured to apply radially inward pressure. A heating element may be located upstream of the series of rollers.

Abstract: A component is provided that includes a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer. The thermoplastic layer includes a plurality of reinforcement particles within a thermoplastic matrix. The thermoset layer is configured from or otherwise includes a thermoset matrix.

Abstract: A cascade array includes a first strongback having a first thermoset or thermoplastic composite material. The cascade array further includes a second strongback having a second thermoset or thermoplastic composite material. The cascade array further includes a first vane that is coupled to the first strongback and the second strongback and includes a third thermoset or thermoplastic composite material.

Abstract: A cascade array vane is provided that includes a vane, a first longitudinal portion, a second longitudinal portion, and at least one coupling feature. The vane includes an airfoil portion extending between a first end and a second end. The first longitudinal portion is disposed at the first end of the vane extending outwardly from the vane. The second longitudinal portion is disposed at the second end of the vane extending outwardly from the vane. The at least one coupling feature is incorporated with at least one of the first longitudinal portion or the second longitudinal portion.

Abstract: A panel includes a core between and connected to a first skin and a second skin. The core includes a corrugated body, a first sidewall and a second sidewall. The corrugated body includes a plurality of corrugations configured from at least a plurality of baffles and a plurality of septums. Each of the corrugations includes a respective one of the baffles and a respective one of the septums. A first cavity extends laterally within the core from a first of the baffles to a first of the septums. The first cavity extends longitudinally within the core from the first sidewall to the second sidewall. The first cavity is fluidly coupled with a passage through a first portion of the first skin. The first portion of the first skin, the first sidewall and the second sidewall are collectively at least partially formed by a ply of material.

Abstract: A component is provided for an aircraft. This aircraft component includes an object and a multi-layer coating. The object includes an object surface. The multi-layer coating includes a barrier layer and a laminar flow layer. The covers at least a portion of the object surface. The barrier layer a fluoropolyether, a silicon rubber and/or a polyurethane. The laminar flow layer covers the barrier layer and forms an exterior surface of the component. The laminar flow layer includes a sol-gel siloxane, a rare-earth oxide and/or a phosphate.

Abstract: A system for forming a thermoplastic may comprise a mandrel configured to receive a thermoplastic charge. The mandrel may rotate about a mandrel axis. A series of rollers may be located circumferentially about the mandrel and configured to apply radially inward pressure. A heating element may be located upstream of the series of rollers.

Abstract: A thermoforming method includes heating a thermoplastic panel to a forming temperature, and compressing the thermoplastic panel between a first tool and a second tool, wherein the thermoplastic panel is bent about a first axis extending along a first direction with respect to the thermoplastic panel in response to being compressed between the first tool and the second tool. The thermoplastic panel may then be cooled to a hardened temperature and disposed between a third tool and a fourth tool. The method further includes heating the thermoplastic panel to the forming temperature, and compressing the thermoplastic panel between the third tool and the fourth tool, wherein the thermoplastic panel is bent about a second axis extending along a second direction with respect to the thermoplastic panel in response to being compressed between the third tool and the fourth tool.

Abstract: A component is provided for an aircraft. This aircraft component includes an object and a multi-layer coating. The object includes an object surface. The multi-layer coating includes a barrier layer and a laminar flow layer. The covers at least a portion of the object surface. The barrier layer a fluoropolyether, a silicon rubber and/or a polyurethane. The laminar flow layer covers the barrier layer and forms an exterior surface of the component. The laminar flow layer includes a sol-gel siloxane, a rare-earth oxide and/or a phosphate.

Abstract: A component is provided that includes a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer. The thermoplastic layer includes a plurality of reinforcement particles within a thermoplastic matrix. The thermoset layer is configured from or otherwise includes a thermoset matrix.

Abstract: An acoustic panel includes a first skin, a second skin and a cellular core vertically between and connected to the first skin and the second skin. The cellular core includes a plurality of cavities, a plurality of sidewalls and a plurality of septums. Each of the plurality of cavities extends vertically through the cellular core between the first skin and the second skin. Each of the plurality of cavities extends laterally within the cellular core between a respective laterally adjacent pair of the plurality of sidewalls. Each of the plurality of septums vertically divides a respective one of the plurality of cavities into a set of fluidly coupled sub-cavities. A set of the plurality of septums is formed by a ply of folded material. Each of the set of the plurality of septums have a four-sided polygonal shape when viewed in a plane that is parallel to the first skin.

Abstract: A cascade array includes a first strongback having a first thermoset or thermoplastic composite material. The cascade array further includes a second strongback having a second thermoset or thermoplastic composite material. The cascade array further includes a first vane that is coupled to the first strongback and the second strongback and includes a third thermoset or thermoplastic composite material.

Abstract: A cascade array vane is provided that includes a vane, a first longitudinal portion, a second longitudinal portion, and at least one coupling feature. The vane includes an airfoil portion extending between a first end and a second end. The first longitudinal portion is disposed at the first end of the vane extending outwardly from the vane. The second longitudinal portion is disposed at the second end of the vane extending outwardly from the vane. The at least one coupling feature is incorporated with at least one of the first longitudinal portion or the second longitudinal portion.

Abstract: A panel includes a core between and connected to a first skin and a second skin. The core includes a corrugated body, a first sidewall and a second sidewall. The corrugated body includes a plurality of corrugations configured from at least a plurality of baffles and a plurality of septums. Each of the corrugations includes a respective one of the baffles and a respective one of the septums. A first cavity extends laterally within the core from a first of the baffles to a first of the septums. The first cavity extends longitudinally within the core from the first sidewall to the second sidewall. The first cavity is fluidly coupled with a passage through a first portion of the first skin. The first portion of the first skin, the first sidewall and the second sidewall are collectively at least partially formed by a ply of material.

Abstract: Systems and methods for manufacturing laser-perforated nanoreinforced materials are disclosed. A honeycomb core may utilize a perforated top sheet and a microperforated overlay film coupled to the perforated top sheet. The perforated top sheet and/or the microperforated film may include thermally conductive nanomaterials. The perforations in the top sheet and the microperforations in the film may be laser drilled. The nanomaterials may dissipate heat generated by the laser drilling, allowing for increased perforation speeds.

Abstract: An inner fixed structure for an aircraft nacelle may comprise a nanoreinforced polyimide composite skin. The nanomaterials may increase thermal conductivity and decrease microcracking in the inner fixed structure. The inner fixed structure may comprise an inner polyimide composite skin, an acoustic core, and an outer polyimide composite skin. The inner fixed structure may be blanketless.