Abstract: A conformable tank includes a body with a plurality of walls defining a cavity in the body, and an internal support structure connected to an internal surface of one of the plurality of walls and protruding into the cavity of the body. The plurality of walls are formed of a first 3D woven composite material. The internal support structure is formed of a second composite material.

Abstract: A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The internal skeleton may be fabricated via a first additive manufacturing system. The skin may be fabricated via a second additive manufacturing system that is different from the first additive manufacturing system.

Abstract: An adhesive joint for an aircraft includes a first aircraft component having a first surface forming one or more isolation grooves, a second aircraft component having a second surface and an adhesive forming a bondline between the first and second surfaces to bond the first aircraft component to the second aircraft component. The adhesive substantially fills the one or more isolation grooves to form at least one disbond arrest boundary. The at least one disbond arrest boundary is operable to prevent a disbond in the bondline from traversing therethrough, thereby preventing the disbond from propagating along the bondline across the at least one disbond arrest boundary.

Abstract: A control surface element for an aircraft, more particularly a spoiler, comprising an upper outer skin element that has an outer air flow face; comprising a lower outer skin element; comprising at least one reinforcement rib; and comprising a core element made of a foam material; wherein the reinforcement rib is positioned between two core segments of the core element.

Abstract: A system includes a septum sleeve, an aperture fitting, and a removable aperture. The septum sleeve is substantially hollow and is configured to be positioned at least partially within a core of an assembly of an aircraft. The aperture fitting is configured to provide an interface to mechanically fasten the removable aperture. The removable aperture is configured to contain one or more electronic components and to be removably positioned at least partially within the septum sleeve.

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A propeller blade spar core includes a leading edge spar foam section surrounded by a first structural layer, a trailing edge spar foam surrounded by a second structural layer, and a third structural layer surrounding both the first and second structural layers.

Abstract: The invention discloses a trailing edge (2) of an aircraft aerodynamic surface, which comprises an upper skin (6) and a lower skin (7), being the upper and lower skins (6, 7) made of composite material. In the trailing edge (2) a lightweight part (1) is assembled at an end section (13) of the upper and lower skins (6, 7). The lightweight part (1) is covered by a metallic sheet (8), and has a “V”-shaped cross section with arms and peak, where the peak of the “V”-shaped cross section has a rounded shape and is located opposite the end section (13) of the upper and lower skins (6, 7).

Abstract: A structural element for reinforcing a fuselage cell of an aircraft is provided. The structural element comprises a reinforcement profile which is made in one piece from a metallic material. The profile is provided with a strap at least in regions. As a result of the strap which is made of a fiber-reinforced layer material or fiber metal laminate and is adhesively bonded, at least in regions, to a flange of the reinforcement profile the structural element has high damage tolerance and advantageous fatigue properties. The fiber metal laminate or layer material is made of a plurality of metal layers and fiber-reinforced plastics material layers which are stacked in alternating fashion and adhesively bonded to one another over the entire surface. The reinforcement profile and the strap are joined by means of a joining layer. Said joining layer is preferably constructed from two prepreg layers and a non-fiber-reinforced adhesive layer.

Abstract: A fuselage segment of an aircraft fuselage is provided with an outer skin and an inner skin that are spaced apart from one another by a core, wherein conduits for system installations are integrated into the core, as well as a method for manufacturing such a fuselage segment.

Abstract: A method and apparatus for manufacturing a composite structure. A filler material with a barrier material for a channel in the filler material is formed. A composite material and the filler material with the barrier material are laid up onto a tool in a shape of the composite structure. The composite material and the filler material in the shape of the composite structure are cured.

Abstract: An airfoil includes at least one precured composite spar having a web and at least one flange integrated with an end of the web. A precured composite skin is attached to the spar by adhesive bonding the skin to the flange.

Abstract: A laminated wing structure includes at least one layer of metal material and at least one layer of a shape memory polymer (SMP) material. The SMP is heated to a temperature in its glass transition band Tg to roll the wing around the air vehicle into a stored position. The metal layer(s) must be thin enough to remain below its yield point when rolled up. In preparation for launch, the SMP material is thermally activated allowing the strain energy stored in the layer of metal material to return the wing to its deployed position at launch. Once deployed, the SMP cools to its glassy state. The SMP material may be reinforced with fiber to form a polymer matrix composite (PMC). SMP may be used to provide shear strain relief for multiple metal layers. By offloading the motive force required to return the wing to its original deployed position from the SMP to the metal, the polymer does not acquire a permanent set and the wing may be deployed accurately.

Abstract: The present invention relates to a method for actively deforming, by feedback control, an aerodynamic profile comprising an elastic material, applied to a part of the surface of the aerodynamic profile, said elastic material being in contact with a fluid flow; said elastic material being able to be deformed by one or more shape memory actuators placed in contact with the elastic material, said actuators being controlled by a computer connected to sensors. This method applies notably to a deformation of an aerofoil of a wing of an aircraft in flight, notably subsonic.

Abstract: A fairing includes a fairing body having a fairing interior and an interior surface and a spray-on insulation foam layer provided on the interior surface of the fairing body.

Abstract: A wing, such as a wing for an unmanned aerial vehicle (UAV), includes a beam or box that can be selectively expanded from a collapsed condition, to increase the thickness of the wing. The beam may include a pair of plates that are close together when the beam is in a collapsed condition, and separate from one another to put the beam in an expanded condition. The plates may be substantially parallel to each other, and may have shape memory foam and/or resilient devices, such as coil springs, between them, in order to provide a force to separate the plates before, during, and/or after deployment of the wing. The expandable/collapsible beam may have a lock mechanism to lock it into place when the beam is in an expanded condition.

Abstract: Devices, systems and methods are disclosed which relate to providing wing designs with payload integration capabilities on existing modularly assembled unmanned aerial vehicles (UAVs). Exemplary embodiments of the present invention present a novel technique of adding payloads to existing UAVs while improving flight performance over existing techniques by maintaining a similar overall weight with improved aerodynamic properties. The technique includes using a reinforced foam core center wing with a fiberglass epoxy skin. A lightweight payload canopy cover integrates onto the center wing as an agnostic enclosure for payloads. The payload canopy cover may contain venting holes for the cooling of electronic payloads. The systems may also include common devices such as antennas, GPS, and batteries for use with a wide range of payloads.

Abstract: An airfoil comprising: a foam housing having a leading edge, a trailing edge, a first end, and a second end; a front spar at least generally extending proximal to and along the leading edge; a rear spar at least generally extending proximal to and along the trailing edge; and a center spar assembly located between the front spar and the rear spar, the center spar assembly including: at least one supporting member extending from the first end toward the second end; a sleeve extending from the first end toward the second end, the sleeve configured to receive a joining member; and an anchor positioned adjacent to the first end, the anchor configured for securing an end of the sleeve and an end of each one of the at least one supporting member at the first end.

Abstract: A composite member with a reinforced rampdown or taper has a composite noodle bonded to an end of a core to fill the taper.

Abstract: An energy absorbing system may include a structure formed of an inner face sheet and an outer face sheet and having a core positioned therebetween. The structure may have a leading edge. An impact member formed of a plastically deformable material may be positioned with the inner face sheet within an area of the leading edge. The impact member may absorb energy from an impact of a projectile with the leading edge and redistributing the energy of the impact to the structure.

Abstract: An energy absorbing apparatus and system for leading edge structures includes an impact member, such as a “bird-band”, of a plastically deformable material of a predetermined configuration positioned with the structure in an area of the leading edge of the structure to absorb energy of an impact of a projectile with the leading edge of the structure, and to redistribute the energy of the impact to the structure, and can break up the projectile, and can increase the impact area. The structure can have one or more sheet members, such as a single sheet, or an inner face sheet and an outer face sheet with a core positioned between the inner face sheet and the outer face sheet. One or more impact members of the plastically deformable material can be positioned with one or more of the single sheet, the inner face sheet, the outer face sheet or the core.

Abstract: A structural element includes the following elements: a carrier element, a reinforcing element, and a sheathing element. At least a portion of the reinforcing element is enveloped by the sheathing element and the reinforcing element is embedded in the carrier element. Materials of the elements are selected to inhibit crack initiation or propagation in the elements and/or from one element to another. An intermediate layer of a different material may be added between elements to further inhibit crack initiation and propagation and to inhibit corrosion, such as galvanic corrosion.

Abstract: An aircraft wing slat is formed from composite materials using lay-up and vacuum bagging techniques. The slat lay-up comprises a central honeycomb core sandwiched between upper and lower composite skins, a pre-cured spar and pre-cured stiffeners. After the lay-up is cured and removed from a lay-up mold, leading edge strengthening ribs and a preformed composite nose skin are installed to complete the slat.

Abstract: A thermal protection system for atmospheric entry of a vehicle, the system including a honeycomb structure with selected cross sectional shapes that receives and holds thermally cured thermal protection (TP) blocks that have corresponding cross sectional shapes. Material composition for TP blocks in different locations can be varied to account for different atmospheric heating characteristics at the different locations. TP block side walls may be attached to all, or to less than all, the corresponding honeycomb structure side walls.

Abstract: A wing panel structure for an aerospace vehicle or the like may include an outer layer of material having a predetermined thickness. A core structure may be placed on at least a portion of the outer layer of material. An inner layer of material may be placed at least on the core structure. The inner layer of material may have a selected thickness less than the predetermined thickness of the outer layer of material.

Abstract: A metallic-composite joint is formed by inserting a metallic member into a slot of a pi-shaped composite preform. The preform is formed from woven carbon fiber in a binder of resin and may or may not be cured prior to assembly. An inert compliant layer is located between the legs of the preform and the metallic member. The resin binder or an adhesive is used to bond the compliant layer to the preform. The compliant layer has a coefficient of thermal expansion that more closely matches that of the preform. The properties of the compliant layer also avoid galvanic corrosion between the carbon in the preform and the metallic member.

Abstract: Aircraft wing assemblies having both composite and metal panels are disclosed. In one embodiment, a wing assembly includes a support structure, an upper panel assembly formed from a metal material and coupled to the support structure, and a lower panel assembly formed from a composite material and coupled to the support structure. The metal material may be aluminum, titanium, or any other suitable metal, and the composite material may be a carbon fiber reinforced plastic (CFRP) material or other suitable composite material. In another embodiment, the upper panel assembly includes a downwardly depending first web portion, and the lower panel assembly includes an upwardly depending second web portion, the second web portion being proximate the first web portion, and an interface member of an isolating material is disposed between the first and second web portions.

Abstract: The present invention is directed toward a laminate composite structure and a method for fabricating a laminate composite structure, wherein the laminate composite structure comprises a solid laminate and a composite sandwich structure. The solid laminate includes a bend having composite pins inserted there through. The composite sandwich structure is comprised of a core material sandwiched between top and bottom composite face sheets.

Abstract: Aircraft wing assemblies having both composite and metal panels are disclosed. In one embodiment, a wing assembly includes a support structure, an upper panel assembly formed from a metal material and coupled to the support structure, and a lower panel assembly formed from a composite material and coupled to the support structure. The metal material may be aluminum, titanium, or any other suitable metal, and the composite material may be a carbon fiber reinforced plastic (CFRP) material or other suitable composite material. In another embodiment, the upper panel assembly includes a downwardly depending first web portion, and the lower panel assembly includes an upwardly depending second web portion, the second web portion being proximate the first web portion, and an interface member of an isolating material is disposed between the first and second web portions.