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 interior trim panel for a vehicle includes a polymer/leather layer having leather particles each having a diameter of less than 5000 micrometers dispersed within a polymer, and a backing layer adhered to the leather layer and providing a support structure for the polymer/leather layer.

Abstract: An interior trim panel for a vehicle includes a leather layer defining a feature having a radius of less than five millimeters, and a backing layer adhered to the leather layer and providing a support structure for the leather layer. A method of forming the interior trim panel includes clamping the leather layer in a frame to securely fix the edges of the leather layer, positioning the leather layer between compression mold dies defining a complementary surface having a feature with a radius of less than five millimeters, and compressing the leather layer between the dies.

Abstract: A method is provided for forming a near-net thermoplastic composite component includes co-spraying a mixture comprising a thermoplastic polymer material and a chopped reinforcing material deposited onto at least one region associated with a tool having a first temperature and defining a near-net component shape. The mixture and adjacent tool is heated to a second temperature while the mixture is on the tool. The first temperature is below the solidification temperature of the thermoplastic polymer material and the second temperature is above the solidification temperature. Then, the mixture is exposed to a negative pressure to promote removal of gases from the mixture and put under compressive force to densify the mixture. The thermoplastic polymer material melts and flows. The tool is cooled to the first temperature and removing the mixture to form the near-net thermoplastic composite component having randomly oriented chopped reinforcement material distributed within a thermoplastic polymer matrix.

Abstract: A method of joining a first workpiece substrate and a second workpiece substrate is disclosed in which a local mold tool is positioned into contact with the first workpiece substrate and the second workpiece substrate. The local mold tool defines a mold cavity and encloses an edge portion of the first workpiece substrate and an edge portion of the second workpiece substrate such that the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate are contained within the mold cavity. Once the local mold tool is positioned, a liquid polymer molding compound is injected into the mold cavity. The liquid polymer molding compound is hardened in the mold cavity into a polymer joint that adheres the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate together.

Abstract: A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

Abstract: A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

Abstract: Presented are manufacturing control systems for fabricating composite-material structures, methods for making/operating such systems, and resin transfer molding techniques for ameliorating race-tracking effects in fiber-reinforced polymer panels. A method for forming a composite-material construction includes confirming, via a system electronic control unit (ECU), that a fiber-based preform is placed in a mold cavity and that opposing mold segments of the molding apparatus are sealed together. A filler, such as a compressible bladder, a cluster of spring-biased pins, or a spray-chopped fiber bed, is introduced into a void between the fiber-based preform and a tool face of one mold segment to thereby eliminate an unwanted resin race track. The system ECU commands a resin pump to inject resin through a primary gate of the molding apparatus and into the mold cavity to thereby impregnate the fiber-based preform with the resin. One or more vents operate to evacuate air from the mold.

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: Systems and methods for additive manufacturing of a metallic component using a metal-powder paste are described. The metal-powder paste is a mixture including a non-uniform metal powder and a flowable additive. The metal-powder paste is applied to a surface of a substrate and spread to thereby produce a uniform-thickness layer in areas corresponding to the metallic component. The flowable additive is driven off using thermal energy to thereby form a layer of the non-uniform metal powder having a uniform thickness. The non-uniform metal powder is then fused to the substrate to thereby form the metallic component.

Abstract: Methods for forming composite articles include providing a non-crimp fabric (NCF) comprising a plurality of fiber plies maintained in a layup by stitching, wherein the stitching exhibits a lower structural tolerance to heat and/or UV light relative to the fiber plies, selectively degrading the stitching in one or more areas using heat or UV light, draping the NCF on a contoured article, applying a polymer matrix material to the draped NCF, and curing the polymer matrix material to form a contoured composite article. The stitching can be degraded in regions of the NCF which, when draped on the contoured article, correspond to topological features of the contoured article. Degrading the stitching can comprise breaking the stitching. The fiber plies can comprise carbon fibers, glass fibers, and/or basalt fibers. The contoured article can be tooling and/or an automotive component. The NCF can be a bi-axial NCF.

Abstract: An underbody assembly for a vehicle includes a plurality of polymer-fiber composite components. The polymer-fiber composite components include a base and a first reinforcement. The base includes a first side and a second side. The base is configured to extend in a longitudinal direction between a front of the vehicle and a rear of the vehicle. The first reinforcement is coupled to the base. The first reinforcement includes a first elongated ridge and a first elongated trough. The first elongated trough is disposed adjacent to the first elongated ridge. The first elongated ridge and the first elongated trough each extend transversely between the first side of the base and the second side of the base. In various aspects, the underbody assembly consists essentially of the polymer-fiber composite components.

Abstract: Compression molding methods for improving the durability and weatherability of a composite material are provided. The methods include disposing a protective surface film on a composite material; adhering the protective surface film to the composite material; and compression molding the protective surface film. The composite material comprises a thermoplastic polymer and a reinforcement material. The protective surface film comprises at least one stabilizer that minimizes or prevents degradation of the underlying composite material when exposed to ultraviolet radiation and/or heat. The composite material may be heated in an oven having an environment comprising oxygen. The protective surface film may be disposed on the composite material prior to the composite material entering the oven; while the composite material is in the oven; or after the composite material exits the oven.

Abstract: An energy-absorbing assembly for a vehicle includes a carrier plate and a plurality of discrete energy-absorbing elements. The carrier plate includes a first polymer and a first plurality of reinforcing fibers. The plurality of energy-absorbing elements each includes a second polymer and a second plurality of reinforcing fibers. The plurality of energy-absorbing elements is fixed to the carrier plate. Each energy-absorbing element of the first plurality of energy-absorbing elements includes an elongated hollow structure defining a longitudinal axis extending nonparallel to the carrier plate. Another energy-absorbing assembly includes a carrier plate and a plurality of discrete energy-absorbing elements. The carrier plate includes a first polymer and a first plurality of reinforcing fibers. The plurality of energy-absorbing elements each includes a second polymer and a second plurality of reinforcing fibers. Each energy-absorbing element includes a transverse wall and is fixed to the carrier plate.

Abstract: An energy-absorbing assembly includes a housing and a plurality of discrete energy-absorbing elements. The housing includes a first wall and a second wall. The first wall and the second wall are spaced apart from one another to at least partially define an interior compartment. Each element of the plurality of energy-absorbing elements includes a polymer and a plurality of reinforcing fibers. The plurality of energy-absorbing elements is at least partially disposed within the interior compartment and fixed to the housing. Each energy-absorbing element of the plurality of energy-absorbing elements includes an elongated hollow structure extending between a first end and a second end. Each elongated hollow structure defines a longitudinal axis extending nonparallel to at least one of the first wall and the second wall. In various alternative aspects, each energy-absorbing element may include a transverse wall.

Abstract: A method of manufacturing a long fiber reinforced thermoplastic filament includes disposing a mixture of fibrous material and thermoplastic material into a hopper of an extruder device and introducing the mixture into the extruder and through an extensional flow die to preserve longer fiber lengths. From the extensional flow die the mixture is passed through a drawing die to create the long fiber reinforced filament.

Abstract: A sealing interface configured to prevent galvanic corrosion of a container having parts made of dissimilar materials includes a first part, a second part, and a sealant. The first part has a first sealing surface and a first exterior surface substantially perpendicular to the first sealing surface. The second part has a second sealing surface and a second exterior surface substantially perpendicular to the second sealing surface. One of the parts includes an external sealing chamfer on the respective sealing surface extending to the respective exterior surface. The sealant at least fills a space formed between the external sealing chamfer and the sealing surface of the other of the parts when the parts are connected, forming a barrier between the parts such that the exterior surfaces of the parts are not in contact and are separated by the sealant. The exterior surfaces may be flush when the parts are connected.

Abstract: A three-dimensional lattice includes a stabilizing grid having grid warp strands and grid weft strands crossing the grid warp strands. Grid cells are defined by adjacent grid warp strands and adjacent grid weft strands intersecting the adjacent grid warp strands. A projecting net has net warp strands and net weft strands crossing the net warp strands. Each subnet in a plurality of subnets uniquely corresponds to a corresponding grid cell. Each subnet includes a net warp strand portion intersecting both of the grid weft strands that define the corresponding grid cell. Each subnet includes a net weft strand portion intersecting both of the grid warp strands that define the corresponding grid cell. The net warp strand portion and the net weft strand portion of each subnet are spaced from a minimum surface defined by the corresponding grid cell.

Abstract: A sealing interface configured to prevent galvanic corrosion of a container having parts made of dissimilar materials includes a first part, a second part, and a sealant. The first part has a first sealing surface and a first exterior surface substantially perpendicular to the first sealing surface. The second part has a second sealing surface and a second exterior surface substantially perpendicular to the second sealing surface. One of the parts includes an external sealing chamfer on the respective sealing surface extending to the respective exterior surface. The sealant at least fills a space formed between the external sealing chamfer and the sealing surface of the other of the parts when the parts are connected, forming a barrier between the parts such that the exterior surfaces of the parts are not in contact and are separated by the sealant. The exterior surfaces may be flush when the parts are connected.