Abstract: Provided is a stack molding machine including an upper mold having formed therein a first runner and a first gate serving as a path of a resin material, a first intermediate plate provided under and combined with the upper mold, and having formed therein a first molding connected to the first gate to mold at least a portion on a first substrate placed under the first intermediate plate, a dummy plate provided under and spaced a certain distance apart from the first intermediate plate, a second intermediate plate provided under the dummy plate, and having formed therein a second molding connected to a second gate to mold at least a portion under a second substrate placed under the dummy plate, and a lower mold having formed therein a second runner and the second gate serving as a path of the resin material, and combined with the second intermediate plate.

Abstract: A composite liftgate system with an inner panel construction having a strengthening channel structure. Structural composite reinforcements are bonded to the inner panel where additional strength is needed to meet predetermined performance requirements. Where the extra structure is needed, no steel or a minimum amounts of steel is used and the structural reinforcements are bonded in place using adhesive prior to application of additional fasteners.

Abstract: Additive manufacturing can involve dispensing a powdered material to form a layer of a powder bed on a support surface of a build platform. A portion of the layer of the powder bed may be selectively melted or fused to form one or more temporary walls out of the fused portion of the layer of the powder bed to contain another portion of the layer of the powder bed on the build platform.

Abstract: The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system includes a graphical user interface (GUI) capable of showing a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. The GUI is capable of displaying the 3-D image as each additional 2-D cross section is scanned by an ultrasonic testing apparatus in real time or near real time, including probable defect regions that contain a flaw such as a hole, crack, wrinkle, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting defect areas within the 3-D image in real time or near real time and providing data regarding each defect area, such as the depth, size, and/or type of each defect.

Abstract: A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

Abstract: A biaxially stretchable laminated fabric composite material includes a four-way stretchable fabric and a barrier film. The barrier film and the fabric are selectively attached at a plurality of individual bond points. When the fabric is in an unstretched state, random folds are formed in the unbonded regions of the barrier film. When the fabric is in a stretched state, the random folds are partially or fully flattened to allow the biaxially stretchable laminated fabric composite material to biaxially stretch.

Abstract: The invention relates to a method for connecting a connection piece to a U-shaped ring anchor for a head module for rail vehicles, the head module consisting predominantly of fiber-reinforced plastic material and having an outer shell and the ring anchor consisting of fiber-reinforced plastic material and being arranged in the roof region of the outer shell as a stiffening means. According to the method, connecting elements are fed through the dry or matrix-material-impregnated, unconsolidated fiber reinforcement structure of the ring anchor.

Abstract: A molding provided with a sheet-shaped composite material section formed from a fiber-reinforced composite material containing reinforcing fibers and a matrix resin, and protruding ribs formed directly on a first surface of the composite material section and containing a thermoplastic resin, wherein the ribs intersect with each other on the first surface, and the mean width t, mean height H and the proportion occupied on the first surface are within specified ranges. A manufacturing method for the molding including a composite material section-forming step for forming the composite material section, and a rib-forming step for forming the ribs so as to satisfy the above conditions.

Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

Abstract: An apparatus is provided for a gas turbine engine. This gas turbine engine apparatus includes a first platform, a second platform, a plurality of vanes and a plurality of beams. The first platform extends axially along and circumferentially about an axis. The second platform extends axially along and circumferentially about the axis. The vanes are arranged circumferentially about the axis. Each of the vanes extends radially across a gas path between the first platform and the second platform. The vanes include a first vane movably connected to the first platform. The beams are arranged circumferentially about the axis. The beams are fixedly connected to the first platform and the second platform. The beams include a first beam extending radially through the first vane.

Abstract: A planar body component for motor vehicles is designed as a fiber composite laminate having a cured main laminate of fiber-reinforced plastic and an additional fiber layer, which is glued to the main laminate and can be decoupled from the main laminate in some sections when force is applied to the planar body component. The additional fiber layer is formed of a non-ductile, dry fiber textile.

Abstract: A method of making deflection members is disclosed. The deflection members are 3D objects that include cross-linkable polymers and are printed directly onto permeable materials utilizing at least two different printer settings.

Abstract: An additively manufactured structure and methods for making and using same. An object can be printed at least partially on an attachment portion. The attachment portion can be bonded to the object upon the printing. The object does not need to be removed from the attachment portion. The need of providing a print surface to allow easy removal of the object is eliminated. The object can be a flat panel and can eliminate the need of printing a large flat layer using additive manufacturing. The attachment portion can be cut prior to the printing, so no trimming needs to be performed after the printing. The attachment portion can be made of a material that has one or more selected properties to expand functionalities of the object. A secondary operation for attaching the attachment portion to the object after the printing can be eliminated.

Abstract: A ball includes a bladder that has a majority weight component of a material of a first material class. The ball includes at least one intermediate layer that is arranged exterior to the bladder and that has a majority weight component of the material of the first material class. The ball includes at least one exterior layer that is arranged exterior to the at least one intermediate layer and that has a majority weight component of the material of the first material class.

Abstract: A liquid composite molding method includes the steps of providing a part mold that has an inlet gate and an exit gate, placing a fabric preform over the part mold, placing a membrane over the fabric preform and securing a pressure cap to the part mold. The pressure cap and part mold together form a pressure chamber with a headspace between the membrane and the pressure cap. The method further includes the step of filling the fabric preform with liquid resin under the membrane while applying pressure within the headspace over the membrane. The method may be practiced with an apparatus that has a pressure chamber, a fabric preform inside the pressure chamber, a membrane over the fabric preform, a resin injection assembly, and a resin extraction assembly. The pressure chamber includes a part mold and a pressure cap. A headspace is formed above the membrane within the pressure chamber.

Abstract: A method and system for fabricating a composite structure is provided. A first vacuum bag is laid down on a surface of a tool. A composite material is positioned on top of the first vacuum bag on the tool. A second vacuum bag covers the composite material. Vacuum pressure is applied to the first vacuum bag and the second vacuum bag. The composite material is cured to form the composite structure. The first vacuum bag is inflated with compressed air to lift the composite structure from the tool.

Abstract: The present disclosure provides a system and method for real-time visualization of a material during ultrasonic non-destructive testing. The system includes a graphical user interface (GUI) capable of showing a three-dimensional (3-D) image of a composite laminate constructed of a series of two-dimensional (2-D) cross sections. The GUI is capable of displaying the 3-D image as each additional 2-D cross section is scanned by an ultrasonic testing apparatus in real time or near real time, including probable defect regions that contain a flaw such as a hole, crack, wrinkle, or foreign object within the composite. Furthermore, in one embodiment, the system includes an artificial intelligence capable of highlighting defect areas within the 3-D image in real time or near real time and providing data regarding each defect area, such as the depth, size, and/or type of each defect.

Abstract: Providing is a heating arrangement for bonding a protective shell to a wind turbine blade, including a heating blanket with a first portion and a second portion of a heatable structure, wherein the first portion and the second portion adjoin at a fold of the heating blanket, wherein the fold is curved equally or substantially equally to a curvature of an edge of the wind turbine blade or of a segment of an edge of the wind turbine blade, wherein the heating blanket is mountable to a surface of the wind turbine blade in such manner that the fold abuts the edge or the segment of the edge and that the first portion and the second portion each abuts the surface of the wind turbine blade.

Abstract: A mold unit (30) defines an elongate cavity (70) and has an injection inlet port (90) for a viscous material at one end of the cavity and an injection outlet port (92) at the other end of the cavity. The mold unit includes a gas vent formed by a gap (G2) between two parts of the mold unit. The gap extends continuously or intermittently in the length direction of the the mold unit, while penetrating through the mold unit in the thickness direction such that it provides fluid communication between an interior space and an exterior space of the cavity. The gap is shaped such that, although gasses pass through, the viscous material does not pass due to fluidity resistance of the viscous material resulting from its viscosity. As a result, the gas vent acts to block leakage of the viscous material while permitting degassing of the viscous material.

Abstract: A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Abstract: A flexible caul for applying pressure to a part comprises a caul member having a plurality of spaced apart gaps therein to provide the caul member with flexibility, and a flexible covering that limits flexing of the caul member.

Abstract: A tooling assembly for manufacturing a porous composite structure. The tooling assembly includes a first tooling member and a second tooling member. The first tooling member includes a first body that defines a first internal volume and a first inlet. The first inlet is fluidly coupled with the first internal volume. The first tooling member also includes a first tooling surface that defines a plurality of first perforations that are fluidly coupled with the first internal volume. The second tooling member includes a second body that defines a second internal volume and a second inlet. The second inlet is fluidly coupled with the second internal volume. The second tooling member also includes a second tooling surface that defines a plurality of second perforations that are fluidly coupled with the second internal volume.

Abstract: A method of making deflection members is disclosed. The deflection members are 3D objects that include cross-linkable polymers and are printed directly onto permeable materials utilizing at least two different printer settings.

Abstract: There is disclosed a molding assembly including a mold having a first surface and an opposed second surface. The mold defines a cavity bounded by two side walls converging toward each other from the first surface toward the second surface. Two mandrels are each removably receivable in the cavity and have a first wall, a second wall opposed to the first wall, an inner wall, and an outer wall opposed to the inner wall. The inner walls face each other and define a gap therebetween for receiving a composite material to be cured. The outer walls are angled and each slidably engage a respective one of the two side walls. A method of co-curing a stiffener and a panel is also disclosed.

Abstract: A method for producing and reinforcing a composite gear includes providing a base material comprising a polymer and forming a composite gear from the base material, the composite gear having a gear body and at least one gear tooth extending from the gear body, the at least one gear tooth having a tooth face, a tooth flank, a tooth fillet, a tooth root, and a tooth tip. The method includes depositing a first metallic material to a first area of the at least one gear tooth of the composite gear, the first area including the tooth root of the at least one gear tooth and depositing a second metallic material to a second area of the at least one gear tooth of the composite gear. The first metallic material is applied in a first thickness and the second metallic material is applied in a second thickness.

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: A device may be provided for additively manufacturing a component, comprising at least one component holder, which is designed to hold the component to be manufactured, and comprising at least one application device, which is designed to heat a thermoplastic material and to deposit it in a predeterminable amount, wherein the device also includes at least one radiation source, which is designed to produce electromagnetic radiation, by means of which at least one partial area of the component can be heated, and the device also includes at least one supply apparatus, which is designed to introduce a fiber reinforcement into the component, which fiber reinforcement includes or consists of an endless fiber. A method for additively manufacturing a component may also be provided.

Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

Abstract: The present invention provides a method for producing a molded article by pressing a composite material containing a resin composition and carbon fibers, wherein the resin composition contains a polyamide resin, a copper compound and potassium halide, and (1) the copper compound content is 0.1 parts by mass or more relative to 100 parts by mass of the polyamide resin.

Abstract: A thermoplastic composite article comprising a porous core layer and a textured film disposed on a first surface of the porous core layer is described. The composite article can be configured as a recreational vehicle building substrate such as a ceiling or interior wall panel.

Abstract: A method for making a mould of an amputation stump, in which the amputation stump is inserted into a liner of a moulding aid, the liner having a longitudinal direction and a circumference, and the liner having an expansion coupling such that when the liner is extended in the longitudinal direction, this necessarily results in a reduction of the circumference.

Abstract: The present invention relates to a prepreg which contains an oriented liquid crystal polymer and a base that uses a continuous carbon fiber bundle as a forming material. The liquid crystal polymer is a thermotropic liquid crystal polymer and the base is included in an amount of at least 25 parts by mass but not more than 550 parts by mass per 100 parts by mass of the liquid crystal polymer.

Abstract: A process for manufacturing a container with a closure-release mechanism relates to thermoforming a plastic sheet to form a container with a clam shell locking system in order to facilitate a secure closure and easy opening packaging container. The clam shell locking arrangement comprises a post which is secured in an aperture when the container is in closed state. The post is a projection or protrusion in a vertical or nearly vertical sidewall of the cover of the thermoformed package and fits securely into the aperture, which is a cut-out made in the outer, and optionally also the inner, wall segments of the vertical or nearly vertical surfaces of the base section of the thermoplastic containers.

Abstract: Provided is a method of applying a protective layer to an outer surfaced of a wind turbine rotor blade, which method includes the steps of preparing a protective layer for application to the outer surface of the rotor blade; providing an air exit channel between the rotor blade and the protective layer; attaching the protective layer to the outer surface of the rotor blade; and extracting air through the air exit channel. Further provided is a wind turbine rotor blade including a protective layer applied to an outer surface of the rotor blade using such a method.

Abstract: A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.

Abstract: A method for manufacturing a multilayer fiber structure includes providing a receiving surface being formed by a first surface region of a contoured tool surface of a forming tool component and a support surface of a support component. Further, at least one fiber layer is formed on the receiving surface by laying down a plurality of fiber tapes onto the receiving surface. A roller device is positioned so as to press the at least one fiber layer against the tool surface and the support component and the roller device are synchronously moved along a curved transition region connects the first surface region to a second surface region of the tool surface. Thereby the at least one fiber layer is abutted against the transition region and the second surface region of the tool surface. Further, a tool system for manufacturing a multilayer fiber structure is disclosed.

Abstract: The invention relates to a molding device (1) and a method for the manufacture of structured or semistructured composite components comprising a polymer resin (50) and a fibrous substrate (51). According to the invention, the device comprises a mold (2) comprising a bottom and a lateral surface, a part (10) that is movable along the lateral surface of the mold, comprising a compression surface (14) forming a cavity (7) with the bottom and the lateral surface (5) of said mold (2), characterized in that the movable part (10) comprises a vacuum-drawing channel (13, 23) opening into a chamber (25, 42) located above the cavity and communicating with said cavity (7).

Abstract: A modular wind turbine blade is described. The modular wind turbine blade comprises first and second blade modules having spar caps embedded within their outer shells. The spar caps taper in thickness resulting in tapered recesses being defined in the outer shells. The tapered recesses in the first and second blade modules are aligned when the modules are placed end-to-end to form a continuous double-tapered channel. A connecting member having a double-tapered structure is bonded in the channel to connect the modules together. The invention also provides a mould for making the blade modules in which the mould surface includes a protruding elongate feature having a tapered portion configured to form the recesses in the outer shells. During layup and moulding of the outer shells, spar caps are supported on top of the tapered portion of the elongate feature.

Abstract: Material sheets are provided which include at least one monolayer, wherein the at least one monolayer has a plurality of drawn unidirectional polymer fibers having a strength of greater than 1.2 GPa and a thickness of less than 100 ?m, and wherein the material sheet includes a bonding agent of less than 13 wt % relative to the total weight of the material sheet.

Abstract: An additive manufacturing method for fabricating a component having a surface substantially free of imperfections may include providing a mold having a configuration corresponding to the component, and depositing a material on at least one surface of the mold to fabricate the component having the surface substantially free of imperfections.

Abstract: Disclosed is a process for manufacturing a part, named composite part, formed from at least one composite material including at least one layer of a reinforcing structure impregnated with a polymer matrix within which the reinforcing structure extends, wherein: a composite blank of the composite part is prepared; and a step of curing the polymer matrix of the composite blank is carried out, exerting a pressure on at least one pressed face of the composite blank. The pressure is exerted in the form of a pressure gradient applied to the pressed face of the composite blank so as to cause the gas present within the composite part to flow from a zone of maximum pressurization to a gas evacuation zone. Also disclosed is a device for manufacturing such a part.

Abstract: A vehicle body reinforcing structure includes: a panel-shaped reinforcing member having a through-hole penetrating through the reinforcing member in a plate-thickness direction of the reinforcing member and located inside a closed-section structure of a vehicle body framework portion; a first panel located at a position closer to an outside of the vehicle than the reinforcing member is; a second panel constituting the closed-section structure with the first panel and located at a position closer to an inside of the vehicle than the reinforcing member is; and a foaming adhesive member filled in an internal space of the closed-section structure, wherein the first panel and the second panel are bonded to each other by the foaming adhesive member penetrating through the through-hole of the reinforcing member, and the foaming adhesive member is filled between the first panel and the reinforcing member and between the second panel and the reinforcing member.

Abstract: A tool is configured to have a changeable shape. The tool comprises a thermoplastic polymeric material, resistive heating elements within the thermoplastic polymeric material, and a flexible casing encapsulating the thermoplastic polymeric material and resistive heating elements.

Abstract: The present invention describes a prepreg for the manufacture of fibre reinforced resin matrix composite materials, the prepreg comprising: a surface film comprising a thermosetting resin and a particulate filler material dispersed therein, and a fibrous layer on which the surface film is disposed, the fibrous layer comprising a plurality of non-woven carbon fibres which are substantially randomly oriented, wherein the fibrous layer has interstices between the carbon fibres dimensioned for absorbing at least a portion of the thermosetting resin during a resin infusion step and filtering at least a portion of the particulate filler material in the surface film to remain in the surface film during the resin infusion step.

Abstract: A method of producing an FRP molded article, the method being suitable for producing a thick FRP molded article, includes: placing a reinforced fiber base material in a cavity of a forming mold, such that a direction in which fiber sheets are laminated together (a sheet lamination direction) is a horizontal direction; impregnating a resin into the reinforced fiber base material by injecting the resin into the cavity in an anti-gravitational direction from an injection port provided below the reinforced fiber base material placed in the cavity; applying pressure in the sheet lamination direction to the reinforced fiber base material impregnated with the resin; and curing the resin impregnated in the reinforced fiber base material.

Abstract: A molding tool and method for producing an interior trim part. A cavity is embodied between a first element and a second element, and a slide is displaceably connected to the first element. A decorative layer is arranged on the first element and a backing is arranged on the second element. A foamable mixture is added to the hollow area between the backing and a reverse side of the decorative layer, such that a foam layer fills the hollow area. A distance between the first element and the second element is increased to enlarge the hollow area. During this process, the slide is pressed against a side facing away from the reverse side of the decorative layer, such that the hollow area is sealed with the reverse side of the decorative layer pressed against a lateral surface of the backing and/or against a lateral surface of the second element.

Abstract: A filter cartridge constructed to prevent an enclosed pleated filter from collapsing into the through-bores formed in a rigid core in high differential pressure applications. The core is modified with reduced-dimension bores to reduce the area of filter material not supported by the core. Alternatively, or in addition, a semi-rigid or rigid core wrap is superposed about the core to add further structural support to the pleated filter. The wrap is formed as a webbed structure with the thickness and spacing of the webbing segments adjusted to partially occlude the underlying core though-bores. This reduces the effective cross-sectional diameter of the through-bores to reduce the overall area of the pleated filter unsupported by the core. The through-bores may have modified shapes to maintain the area of the through-bore and reduce the distance of the through-bore center point from portions of the core wall defining the through-bore. The core also may be modified with clustered through-bores regions.

Abstract: A thin erosion control mattress system and method of protecting coastal structures and riverbanks against bearing failure and erosion from waves and current is disclosed. The thin mattress system includes geotextile fabric bonded to a tensile element (such as geogrid) and sand/gravel or other fill material confined in the mattress with connection elements (such as rivets) at specific intervals. The geogrid, which can be biaxial or multi-axial, provides tensile strength for picking during installation, improving foundation support and rigidity to the mattress system. The rivets function as spacers and tension elements to prevent bulging of the mattress, and are designed and spaced to temporarily secure the mattress in place for uniform filling and installation. The bonded geotextile-geogrid mat is typically sewn on all sides and filled with sand or gravel at designated fill ports. Further, a method of fabricating the thin mattress system is provided.

Abstract: Apparatus for heating fluids through rotary magnetic induction, which has at least one rotating central disc of magnets and at least one bilateral heat exchanger, wherein the magnet disc comprises at least one pair of magnets disposed in such disc and whose configuration exposes the magnets to both sides of the disc with alternating polarity on each side to generate on both sides an agitated magnetic field, and wherein at least one heat exchanger, comprising at least one low resistivity metal surface, is disposed adjacent to each side or face of the magnet disc in order to expose its metal surface to the agitated magnetic field, getting heated and transmitting such heat to a fluid circulating within at least one configured conduit located inside the heat exchanger.

Abstract: A method for molding composite material such as a spar formed with a curved corner part is provided with: a first shaping step of shaping a laminate so that the board thickness of the laminate is reduced from the outside of the corner part toward the inside thereof, the laminate having the corner part curved at a first bending angle and comprising fiber sheets laminated to each other; and a second shaping step of curving the corner part of the laminate to form a second bending angle smaller than the first bending angle, and shaping the laminate so that the board thickness of the laminate is reduced from the inside of the corner part toward the outside thereof.