Abstract: Methods, systems and apparatuses are disclosed for making composite prepreg stacks comprising an outer layer of thermoplastic film that is co-cured with the thermoplastic layer comprising a compressive force on the composite material, along with coated composite materials and larger structures comprising the coated composite materials made according to the disclosed methods.

Abstract: Methods and an apparatus are presented. A bulk molding compound is consolidated by sending the bulk molding compound through a die breaker and an extrusion die of a consolidation system.

Abstract: An apparatus (100) for depositing a radius filler (102), made of a homogeneous material, into a groove (104), formed in a workpiece (106) comprises a chassis (110), first means (120) for extruding the radius filler (102) along an extrusion axis (112), second means (130) for providing the homogeneous material to the first means (120), and third means (140) for compacting the radius filler (102) in the groove (104). The apparatus (100) also comprises a first sensor (150) configured to provide first-sensor output. The apparatus (100) further comprises a controller (180), operatively coupled to the first means (120), the second means (130), and the first sensor (150). Based on the first-sensor output, the controller (180) is configured to determine the first geometric characteristics of the groove (104).

Abstract: A method for forming a composite structure includes the steps of: forming a fiber-reinforced polymer paste to a shape of a cavity of a dry fiber preform structure; heating said dry fiber preform structure having said fiber-reinforced polymer in said cavity to an infusion temperature; infusing resin into said dry fiber preform structure and around said fiber-reinforced polymer; and curing said resin-infused fiber preform structure and said fiber-reinforced polymer at a cure temperature higher than said infusion temperature.

Abstract: A method and apparatus for transforming a finite element model is provided. A set of joint elements to the finite element model of a structure is created at a set of joint locations in the finite element model of the structure. A local coordinate system is assigned to each of the set of joint elements that is independent of a global coordinate system of the finite element model to generate a transformed finite element model. The transformed finite element model is generated with improved consistency and efficiency.

Abstract: A system for depositing a composite filler material into a channel of a composite structure includes an end-effector configured to extrude a bead of the filler material into the channel. The filler material can comprise a first group of relatively long fibers, a second group of relatively short fibers and a resin. A drive system is configured to move the end-effector relative to the channel, and a position sensor is configured to detect the position of the bead relative to the channel. A controller is configured to operate the drive system in response to the detected position and to operate the end-effector to heat and compress the filler material so as to orient the longer fibers in a substantially longitudinal direction relative to the channel and the shorter fibers in substantially random directions relative to the channel when the bead is extruded into the channel.

Abstract: A method for sealing a fastener employs a mold which provided with an inlet port for molding material. The mold is then positioned over a fastener and the mold is sealed against a structure. A moisture cured polyurethane reactive adhesive (MCRPA) as a molding material is then heated and injected into the mold. Upon solidification of the MCRPA, the mold is then removed to expose the MCRPA to atmospheric moisture and cured to leave an in-situ molded cap formed over the fastener and sealed to the structure.

Abstract: A system for depositing a composite filler material into a channel of a composite structure includes an end-effector configured to extrude a bead of the filler material into the channel. The filler material can comprise a first group of relatively long fibers, a second group of relatively short fibers and a resin. A drive system is configured to move the end-effector relative to the channel, and a position sensor is configured to detect the position of the bead relative to the channel. A controller is configured to operate the drive system in response to the detected position and to operate the end-effector to heat and compress the filler material so as to orient the longer fibers in a substantially longitudinal direction relative to the channel and the shorter fibers in substantially random directions relative to the channel when the bead is extruded into the channel.

Abstract: A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.

Abstract: A consolidation system configured to consolidate a bulk molding compound, the apparatus comprises a barrel, a low compression first stage within the barrel, a high compression second stage within the barrel coupled with the low compression first stage, a die breaker coupled to the high compression second stage, and an extrusion die coupled to the die breaker. The low compression first stage includes a low compression screw for mixing and compressing a bulk molding compound comprising a resin and fillers. The high compression second stage includes a high compression screw for compressing the bulk molding compound into a compressed material. The die breaker comprises at least one of a plurality of holes or a plurality of slots.

Abstract: A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

Abstract: Methods, systems and apparatuses are disclosed for making composite prepreg stacks comprising an outer layer of thermoplastic film that is co-cured with the thermoplastic layer comprising a compressive force on the composite material, along with coated composite materials and larger structures comprising the coated composite materials made according to the disclosed methods.

Abstract: A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

Abstract: A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.

Abstract: A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

Abstract: A method for sealing a fastener employs a mold which provided with an inlet port for molding material. The mold is then positioned over a fastener and the mold is sealed against a structure. A molding material is then injected into the mold. The mold is then removed to leave an in-situ molded cap formed over the fastener and sealed to the structure.

Abstract: Systems and methods are provided for fabrication of short-fiber composites. One embodiment is a method for forming a short-fiber composite. The method includes forming a bed of randomly oriented dry fibers on a base, drawing resin into the bed in response to pressure to form a mixture of randomly oriented fibers impregnated with thermoset resin, perturbing the mixture while preserving fiber length at the mixture and degassing the mixture, and extruding the mixture to form a preform.

Abstract: A method and apparatus for sealing a fastener that extends through a surface. The apparatus comprises a housing having a base and cap, wherein the cap is configured to cover a portion of a fastener extending through a surface, and wherein the housing is configured to apply suction to the surface.

Abstract: Actuatable microstructures and methods of making the same are disclosed. An example a sheet includes a first side including an elastomeric material and a second side opposite the first side. The sheet defines sealed channels. In response to a pressure differential across the elastomeric material, the elastomeric material is to be in a deformed position relative to the sealed channels to define microstructures.

Abstract: A nozzle for extruding a composite material from an extruder barrel. The nozzle includes a body and a tapered nozzle passage extending through the body. The tapered nozzle passage having a nozzle inlet opening configured to interface with the extruder barrel, and a nozzle outlet opening, where the tapered nozzle passage has a contoured nozzle passage surface extending between the extruder barrel and the nozzle outlet opening with smooth transitions, free of angles, so that each nozzle passage surface portion, having a corresponding contour, transitions smoothly to each other nozzle passage surface portion, having a respective different contour, from the nozzle inlet opening to the nozzle outlet opening, and the nozzle outlet opening is defined by at least a first edge and a second edge that intersect each other at an acute angle.