Abstract: Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Abstract: A system for curing a composite part, includes a mandrel configured to receive and support the uncured composite part; a plurality of expandable pellets disposed on the uncured composite part; and a mold configured to hold the mandrel, the uncured composite part, and the plurality of expandable pellets, wherein the plurality of expandable pellets are configured to expand and apply a positive pressure to the uncured composite part according to a change in condition or triggering event, and wherein each of the plurality of expandable pellets includes a blowing agent, a polymer matrix configured to hold the blowing agent, and a flexible skin configured to encapsulate the polymer matrix and the blowing agent, wherein the flexible skin is at least partially permeable with respect to the blowing agent or a gas released by the blowing agent.

Abstract: A method for indicating a sanitation status of a surface may comprise contacting a coating on a surface with a cleaning composition, wherein the coating comprises a chromic material and exhibits a baseline optical state under illumination with light having a first wavelength prior to contact with the cleaning composition and an altered optical state under illumination with light having a second wavelength after contact with the cleaning composition, the cleaning composition configured to induce a switch from the baseline optical state to the altered optical state; and illuminating the coating with the first wavelength of light, the second wavelength of light, or both, to reveal a sanitation status of the surface. Systems for indicating a sanitation status of a surface are also provided.

Abstract: Methods of manufacturing composite workpieces that include positioning a heat-generating element proximate to an uncured composite workpiece, triggering the heat-generating element to produce an exothermic chemical reaction or exothermic physical reaction so that the temperature of the uncured composite workpiece is raised to a predetermined first temperature, and curing the composite workpiece while it is at a temperature that is at least the predetermined first temperature.

Abstract: Methods of manufacturing composite workpieces that include adding an expandable element to an internal volume of a constraining container proximate to a uncured composite workpiece supported on a rigid form, where the expandable element is configured to expand when a predetermined change is produced in an attribute of the expandable element; expanding the expandable element by producing the predetermined change in the attribute of the expandable element, so that an expansion of the expandable element applies pressure to the workpiece supported on the rigid form within the internal volume, and curing the composite workpiece while the resulting pressure is applied to the workpiece supported on the rigid form.

Abstract: Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Abstract: A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets by creating a resin affinity portion and a resin repellant portion on the sheets. The resin affinity portion and the resin repellant portion forms the venting pathways. A honeycomb substrate is then formed from the sheets.

Abstract: A honeycomb core includes a honeycomb substrate comprised of a number of sheets. A number of traces are printed onto the sheets of the honeycomb substrate. A number of integrated electronic devices are disposed within the honeycomb substrate. The integrated electronic devices are electrically coupled to the traces.

Abstract: Methods and apparatus to couple a decorative layer to a core layer of a panel via a barrier layer are disclosed. An example apparatus includes a decorative layer coupled to a panel. The panel has a core layer. The example apparatus includes a barrier layer disposed between the core layer and the decorative layer. The barrier layer is to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.

Abstract: Methods and apparatus to couple a decorative layer to a core layer of a panel via a barrier layer are disclosed. An example apparatus includes a decorative layer coupled to a panel. The panel has a core layer. The example apparatus includes a barrier layer disposed between the core layer and the decorative layer. The barrier layer is to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.

Abstract: Skinned cell structures and methods of producing the same are disclosed. A disclosed example apparatus includes a placer to place foamable structures together to define a bundle, a restrainer to restrain the bundle, an activator to activate the foamable structures to expand and form a cell structure within the restrainer, a trimmer to trim the cell structure to define a core, and an assembler to couple a skin to the core to define the skinned cell structure.

Abstract: Fabrication system and associated methods of fabricating a sandwich panel. In one embodiment, a method includes holding a first skin and a second skin of the sandwich panel with a gap between opposing faces of the first skin and the second skin, and expanding a foamable material between the first skin and the second skin to form a foam core of the sandwich panel.

Abstract: A method includes providing a structure having a surface, treating a portion of the surface to modify a wettability of the portion of the structure, and forming at least one liquid flow path on the surface through said treating.

Abstract: A panel assembly (such as for an internal cabin of an aircraft) includes at least one liquid flow path formed on at least one surface through surface treatment. The at least one liquid flow path is formed in relation to at least one bank on the at least one surface. The at least one liquid flow path is configured to divert liquid to a desired location.

Abstract: Prior to curing a composite workpiece assembly, an expandable element can be inserted into a cavity of the workpiece assembly. The expandable element is configured to expand when a predetermined change is produced in an attribute of the element. The attribute can be a temperature of the element. The element is expanded by producing the predetermined change, and the workpiece assembly is cured while the expanded element is in the cavity, so that the expanded element applies positive pressure to inner surfaces of the cavity during curing. The expanded element can be removed from the cavity after curing. The expanded element can comprise a plurality of expandable pellets.

Abstract: Methods of recovering and/or recycling expanded polymer tooling, the methods including collecting expanded polymer tooling, reducing the collected expanded polymer tooling into smaller particles, treating the reduced expanded polymer tooling in order to yield an at least partially purified recovered polymer composition, and then collecting the at least partially purified recovered polymer composition. The at least partially purified recovered polymer composition can then be used to form new expandable polymer tooling.

Abstract: Methods and apparatus to form venting pathways in pressure sensitive adhesives for laminate stacks are disclosed. An example method includes forming a laminate stack including a gas permeable nonwoven layer and a pressure sensitive adhesive layer. The pressure sensitive adhesive layer has a first surface and a second surface located opposite the first surface. The first surface contacts the gas permeable nonwoven layer. The method further includes processing the laminate stack by reducing a ductility of the pressure sensitive adhesive layer such that venting pathways are formed in the pressure sensitive adhesive layer in response to a mechanical strain applied to the pressure sensitive adhesive layer via a trapped gas. The venting pathways extend through a thickness of the pressure sensitive adhesive layer to enable the trapped gas to pass through the pressure sensitive adhesive layer from the second surface to the first surface.

Abstract: An additive manufacturing system is disclosed and includes a first heating element configured to receive a first supply of thermoplastic material and a second heating element configured to receive a second supply of plastic material. A foaming agent is incorporated into the second supply of plastic material and is configured to expand at an activation temperature. The additive manufacturing system also includes a control module in electronic communication with both the first heating element and the second heating element. The control module executes instructions to instruct the first heating element to heat the first supply of thermoplastic material to a first extrusion temperature and instruct the second heating element to heat the second supply of plastic material to a second extrusion temperature. The second extrusion temperature is equal to or greater than the activation temperature of the foaming agent.

Abstract: Decorative laminates having an open-cell foam layer are disclosed herein. An example decorative laminate includes a decorative layer, an open-cell foam layer coupled to the decorative layer and an adhesive layer coupled to the open-cell foam layer.

Abstract: Methods and apparatus to form venting channels on a panel for a decorative layer are disclosed. An example method includes contacting an outer surface of a tool to an outer resin layer of a panel. The outer surface of the tool has protrusions. The example method includes moving the outer surface of the tool on the outer resin layer of the panel in a first direction to cause the protrusions of the tool to form first venting channels on the outer resin layer of the panel and coupling a decorative layer to the outer resin layer of the panel via an adhesive layer. The first venting channels are to vent at least one of gas or vapor away from the decorative layer to deter separation of a portion of the decorative layer from the outer resin layer.