Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.

Abstract: An enclosure capable of supporting one or more phyla of living plants and organisms includes various panels that form the enclosure along with at one front door panel movable to provide access to the interior of the enclosure. A water inlet port is arranged in the top assembly. A drainage system is located on the bottom of the enclosure includes a sloped drainage panel, a sump, and a drain tube. The enclosure further includes an air circulation and ventilation system having the upper vent screen and a lower vent screen separable by a circulation distance that generates a chimney effect within the enclosure. The enclosure may also include a microfauna trough on top of the drainage panel.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.

Abstract: A slat can assembly with a slat can body includes at least one full ply of a composite fiber sheet material and a plurality of elongated, unidirectional fiber ply strips that are arranged into the shape of the slat can body. At least some of the unidirectional fiber ply strips are laid over the full ply. And, the full ply and the elongated, unidirectional fiber ply strips cooperate to provide a contoured shape defined by a cellular core member.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite trailing edge structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers placed onto pressurizable members to form continuous fore and aft loops. In turn, the loops may be structurally functional to transfer loads from the trailing edge structure to a wing center section. The trailing structure may include may include fillers and/or a metallic insert, wherein the metallic insert may provide a lightening strike capability for the trailing edge structure.

Abstract: An enclosure capable of supporting one or more phyla of living plants and organisms includes various panels that form the enclosure along with at one front door panel movable to provide access to the interior of the enclosure. A water inlet port is arranged in the top assembly. A drainage system is located on the bottom of the enclosure includes a sloped drainage panel, a sump, and a drain tube. The enclosure further includes an air circulation and ventilation system having the upper vent screen and a lower vent screen separable by a circulation distance that generates a chimney effect within the enclosure. The enclosure may also include a microfauna trough on top of the drainage panel.

Abstract: A slat can assembly with a slat can body includes at least one full ply of a composite fiber sheet material and a plurality of elongated, unidirectional fiber ply strips that are arranged into the shape of the slat can body. At least some of the unidirectional fiber ply strips are laid over the full ply. And, the full ply and the elongated, unidirectional fiber ply strips cooperate to provide a contoured shape defined by a cellular core member.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with cored members embedded there between. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The cored members may be selectively located on various interior and exterior regions or surfaces of the composite structure.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with cored members embedded there between. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The cored members may be selectively located on various interior and exterior regions or surfaces of the composite structure.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of fiber plies. The fiber plies are arranged on a pressurizable member that may become an integral part of the final product, or may be removed before the product is finalized. The pressurizable member may take the form of a hollow blow molded or rotomolded thermoplastic component or a superplastic formed metallic component having an opening such that the pressurizable member may be vented or pressurized and thus expanded against the fiber plies. In addition, a number of the pressurizable members may be joined in fluid communication, where they may each have different configurations, yet be arranged to form a large, complex-shaped lay-up surface for the fiber plies. The arrangement of the fiber plies onto the pressurizable members may produce integral I-Beam stiffeners, ribs, flanges, and other complex shaped structural components.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite trailing edge structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers placed onto pressurizable members to form continuous fore and aft loops. In turn, the loops may be structurally functional to transfer loads from the trailing edge structure to a wing center section. The trailing structure may include may include fillers and/or a metallic insert, wherein the metallic insert may provide a lightening strike capability for the trailing edge structure.

Abstract: A method for making an environmental control system duct for an aircraft includes making intermediate mandrels using an acetal material in a rotomolding process. With the mandrels made, the environmental control system duct may be created by laying up fiber plies onto the mandrel, bagging the assembly and then curing the assembly. Lastly, the acetal resin mandrels are removed by breaking them out of the post-cured duct.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with cored members embedded there between. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The cored members may be selectively located on various interior and exterior regions or surfaces of the composite structure.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite assembly may be formed by aligning complex-shaped, three-dimensional, pressurizable members to form fiber reinforced composite assemblies. More specifically, the pressurizable members may include indexing and interlocking features for alignment with one another and possibly with other structural components that may be embedded in the assembly. In one embodiment, the indexing features permit the pressurizable members to be snap fit together. In another embodiment, an interlocking member is received in grooves formed in the macro-cellular cores. The interlocking member and thus the grooves may be selected to create uniquely shaped stiffeners for the composite assembly.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of fiber plies. The fiber plies are arranged on a pressurizable member that may become an integral part of the final product, or may be removed before the product is finalized. The pressurizable member may take the form of a hollow molded thermoplastic component or even a metallic component having an opening such that the pressurizable member may be pressurized and thus expanded against the fiber plies. In addition, a number of the pressurizable members may be joined in fluid communication and arranged to form a large, complex-shaped lay-up surface for the fiber plies. The arrangement of the fiber plies onto the pressurizable members may produce integral I-Beam stiffeners, ribs, flanges, and other complex shaped structural components. The fluid medium employed for pressurization may be a gas or a liquid.