Abstract: A method for forming a composite component, the method comprising: providing a first mould tool and a second mould tool, the first and second mould tools being configured so as to be capable of defining at least part of a mould cavity between them, and the second mould tool having a moulding surface defined by at least two demountable mould bodies; attaching the first mould tool to a press at a first workstation; subsequently, at a second workstation spaced from the first workstation, loading at least part of the second mould tool with reinforcement material whilst the first mould tool remains attached to the press at the first workstation; moving the second mould tool to the press at the first workstation in such a position as to confront the first mould tool; causing the press to effect relative movement of the first and second tools to bring the first and second tools into mating arrangement so as to define a mould cavity therebetween; and setting in shape the reinforcement material located in the mould ca

Abstract: The present invention relates to vacuum forming process for moulding a thermoset material and a start-up process for moulding a thermoset material. The present invention also relates to articles produced by the vacuum forming process.

Abstract: A method of forming a bladder cast ceramic matrix composite (CMC) article including infiltrating a CMC substrate positioned in a cavity of a mold body with a slurry. The CMC substrate includes reinforcement material defining inner spaces. The slurry includes solid particles and a carrier material. During infiltration, the slurry at least partially fills at least a portion of the inner spaces of the CMC substrate. The method also includes inflating at least one bladder that is coupled to the mold body and disposed within the cavity such that a surface of the at least one bladder in an inflated configuration contacts at least one surface of the CMC substrate. The method also includes drying the slurry to remove at least a portion of the carrier material form an infiltrated CMC and deflating the at least one bladder.

Abstract: A press tool and a method for forming a cutting insert green body. The press tool includes a first and a second core rod. Both core rods are movably arranged along an axis. When both core rods are in a press position, their respective contact surfaces contact each other and when both the first and second core rods are in a release position, their respective contact surfaces are separated. The first core rod includes a base body having a forwardly facing abutment surface and a piston having a shaft and a head. The piston is movable to a plurality of extended positions and to a retracted position, in which the abutment surface of the head abuts against the abutment surface of the base body. When both the first core rod and the second core rod are in their respective press positions, the piston is in the retracted position.

Abstract: A method for forming a composite part includes positioning a composite ply over a forming surface of a forming tool, moving a forming feature into engagement with the composite ply to yield a formed ply, and, after the moving, securing the formed ply relative to the forming tool.

Abstract: Thermoplastic forming tools and assemblages are provided for forming thermoplastic components. In particular, thermoplastic forming tools and assemblages are provided for forming thermoplastic components having precision micro-scale features and reproducible macro-scale dimensions. The thermoplastic forming assemblages can include at least a bottom tool and a top tool having a rigid tool body and an elastomer layer conformally coating at least a portion of both rigid tool bodies. The bottom and top tool can be so dimensioned that, when in the closed position, they define a cavity forming the thermoplastic component. The rigid tool bodies provide the reproducible macro-scale dimensions in the thermoplastic component, while the elastomer layers form and release the precision micro-scale features in the thermoplastic component when formed.

Abstract: An air intake of a turbojet engine nacelle includes an air intake lip, an annular structure, a rear partition, and at least one acoustic attenuation structure. The annular structure includes at least a part of an outer fairing and an inner fairing joined to each other by the air intake lip. The rear partition is connected to the inner fairing. The acoustic attenuation structure is attached to the inner fairing of the annular structure. At least part of the outer fairing, the air intake lip and the inner fairing are integral with each other.

Abstract: A breather used for vacuum bag compaction of a composite laminate part is semi-permanently installed on a compaction tool. The breather is a channel member having an internal passageway that routes air and volatiles from the vacuum bag to a vacuum port in the tool.

Abstract: A curing mold for manufacturing a turbomachine part made of composite material from a preform produced by draping pre-impregnated materials includes: a first body and a second body designed to be attached to each other and jointly defining a fixed air gap for receiving the preform and itself including a molding part of complementary shape with the part to be manufactured and intended to receive a portion to be molded of the preform, and at least one additional part located in a peripheral space of the air gap and intended to receive an additional portion forming an edge of the preform; a heating member designed to heat the preform in the air gap to a first temperature; at least one inflatable bladder housed in the first or second body, facing an additional part of the air gap; a member for injecting a pressurized fluid inside the bladder(s).

Abstract: Provided is a vacuum assisted resin transfer molding method for producing a component, in particular a spar cap, of a rotor blade including a lightning protection system, wherein the vacuum assisted resin transfer molding method includes the steps of: a) placing) an electrically conductive beam fiber material of an electrically conductive beam, an electrically conductive fiber mat and an electrical conductor of the component in a mold arrangement electrically connecting the electrically conductive beam fiber material to the electrical conductor by means of the electrically conductive fiber mat, wherein an electrical connection between the electrical conductor and the electrically conductive fiber mat is generated, c) subjecting the mold arrangement to underpressure, d) applying an external pressure on the electrical connection from outside the mold arrangement, e) injecting resin into the underpressurized mold arrangement, and f) applying heat to the mold arrangement for curing the resin.

Abstract: Devices and methods for producing a T-shaped semifinished product from a multiply non-crimp fabric with reinforcing fibers for a composite material. The product has a web and a flange. The device includes a web forming tool, with which a web portion of the non-crimp fabric is clamped in place, a forming tool, with which plies of a flange portion of the non-crimp fabric are split into two parts, a depositing device, with which a tube body is deposited on the flange portion formed into the flange, a holding tool, with which a clearance between the holding tool and the flange is formed, and a filling device, with which the tube body is filled with a gas such that the tube body fills the clearance and firmly holds the flange portion formed into the flange, and alternatively, a magnetic force can be generated between a sheet and the web forming tool.

Abstract: A method, apparatus, and system for applying a vacuum-based pressure on an uncured composite structure. Membranes are bonded to a boundary of a caul. The membranes include positive features that define vacuum channels. The membranes are spliced to each other. The positive features that define the vacuum channels in the membranes are aligned to each other during splicing of the membranes. The membranes spliced to each other and bonded to the caul to form an integrated caul. The integrated caul applies a pressure on the uncured composite structure during operation of the integrated caul.

Abstract: One embodiment of a method according to the present disclosure may use an outer member having the required structural rigidity and/or structural integrity such that no thermoforming tool, no support base, no fixture, no cover, no caul plate, no bag, and/or no table are required to make the part as desired. Substrate lay-up may be placed around all or a portion the outer member. A cover may be positioned over the outer member and the pressure within an interior portion of the outer member and cover may be reduced to less than ambient pressure and resin may be introduced to interact with the substrate lay-up and allowed to cure.

Abstract: A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.

Abstract: An apparatus for processing a composite structure includes a first processing-tool and a second processing-tool that are movable between an open position, in which the first processing-tool and the second processing-tool are separated from each other, and a closed position, in which the first processing-tool and the second processing-tool are configured to be sealed to each other. In the closed position, the first processing-tool and the second processing-tool are configured to be sealed to a mandrel-tool, located between the first processing-tool and the second processing-tool and supporting the composite structure. In the closed position, the first processing-tool, the second processing-tool, and the mandrel-tool form a vessel, configured to apply at least one of pressure and heat to the composite structure.

Abstract: Methods and apparatus involved in the process of hardening a composite part are disclosed herein. The methods include applying a preform to a mandrel, covering the preform with a caul plate, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel and hardening the preform into a composite part while the caul plate is held against the preform. The apparatus include a mandrel, a caul plate which defines a surface of a preform and where the caul plate may include a rigid material and seals disposed between the mandrel and the caul plate. In an additional aspect, the apparatus may include a sealed chamber with a mandrel and a caul plate and a circumferential seal between the mandrel and the caul plate.

Abstract: A flexible inner socket is fabricated by forming a pre-socket. The pre-socket includes a body formed with an opening and an enclosed end. The enclosed end is opposite to the opening. The body of the pre-socket has an outer circumference that is smaller than the inner circumference of the rigid prosthetic socket. Different portions of the body may have different thicknesses. The preform socket is heated. After the heating, the flexible inner socket is formed by molding the pre-socket onto the inner surface of the rigid prosthetic socket to form the flexible inner socket. The inner circumference of the rigid prosthetic socket is reduced by a thickness of the flexible inner socket when the flexible inner socket is attached to the inner surface of the rigid prosthetic socket. An opening of the flexible inner socket may be trimmed after the formation to fit contours of an opening of the rigid prosthetic socket.

Abstract: Systems and methods are provided for mixing parts of a thermoset resin during impregnation of a composite preform. One embodiment is a method that includes positioning a composite preform at a forming tool, flowing a first part of the thermoset resin into a mixing chamber at the forming tool, flowing a second part of the thermoset resin that is chemically distinct from the first part of the thermoset resin into the mixing chamber, mixing the first part and the second part to form the thermoset resin within the mixing chamber, and infusing the thermoset resin from the mixing chamber into the preform.

Abstract: A method for bending a flexible panel includes first, providing an airbag assembly; second, inflating the airbag assembly; next, abutting against the bending area with the airbag assembly; and lastly, bending the flexible panel by pivoting on the airbag assembly so that a bent portion of the flexible panel tightly contacts a surface of the airbag assembly, and the terminal area is located behind the flexible panel. The airbag assembly includes a housing and an elastic film. The housing includes at least one outlet and at least one inlet. The elastic film wraps the housing to form a gas chamber. The outlet and the inlet communicate with the gas chamber.

Abstract: A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

Abstract: A system for infusing liquid resin into a sheet of fibrous material comprises a tool and a permeable media layer, configured to have the sheet therebetween. The system further comprises a non-permeable bladder, configured to be sealed to the tool about the sheet of fibrous material and the permeable media layer such that the sheet of fibrous material and the permeable media layer are sealed between the non-permeable bladder and the tool. The system additionally comprises an inlet, selectively fluidically coupleable with the permeable media layer to deliver liquid resin to the permeable media layer. The system also comprises an outlet, selectively fluidically coupleable with the permeable media layer to create a pressure differential across the non-permeable bladder. The system further comprises a permeability control valve, selectively operable to adjust the permeability of the permeable media layer.

Abstract: A method of manufacturing a composite rim includes following steps of: disposing a composite material on an outer surface of an air bag to form a semi-formed rim, wherein the air bag is a completely closed annular tube without any through opening on the outer surface and contains a thermal expansion material thereinside; disposing the semi-formed rim in a mold; and heating the thermal expansion material so that the thermal expansion material expands and inflates the air bag and the semi-formed rim is then solidified.

Abstract: In one embodiment, a method for making a high density structural composite includes depositing a plurality of fibrous materials on or adjacent a first plate or surface. A polymer liquid is deposited onto the plurality of fibrous materials to form a composite mixture. A first cyclic pressure is applied onto the composite mixture to compress the composite mixture. In some embodiments, the cyclic pressure may then be reduced to a valley pressure to complete a pressurization cycle. In some instances, the valley pressure may be below atmospheric pressure to induce trapped air and volatile gases to escape from the composite mixture before curing. The pressurization cycle may be repeated. A second pressure, which may be a constant pressure in some embodiments, may be applied to the composite mixture using, in some embodiments, a second plate until the polymer liquid has at least partially cured or partially solidified.

Abstract: A system for curing a thermoset composite may include a tooling die configured to receive and support an uncured thermoset composite part and to heat the uncured thermoset composite part; a pressure media bag configured to be placed over the uncured thermoset composite part disposed on the tooling die and including a pressure media; and a mechanical press configured to apply a consolidation pressure to the uncured thermoset composite part disposed on the tooling die, the pressure media bag may be configured to distribute the consolidation pressure applied by the mechanical press to the uncured thermoset composite part disposed on the tooling die.

Abstract: A method for forming a seal between structural components includes placing a retainer flap on a first side of a first structural component over a first channel within the first structural component and over a second channel within the first structural component such that the retainer flap, the first side of the first structural component, and a second structural component form a cavity. The first channel extends between the first side of the first structural component and a second side of the first structural component that is opposite the first side. The second channel extends between the first side of the first structural component and the second side of the first structural component. The method also includes evacuating the cavity through the first channel, thereby forcing the retainer flap against the second structural component and forcing a sealant to flow through the second channel into the cavity.

Abstract: According to one implementation, a preform shaping apparatus includes a rigid mold and a pressurizing jig. The rigid mold has a shape corresponding to a shape of a preform which has been shaped. The pressurizing jig presses an unshaped material of the preform to the rigid mold at different positions and different timings. Further, according to one implementation, a method of shaping a preform includes: producing the shaped preform by pressing an unshaped material of the preform to a rigid mold at different positions and different timings; and using a pressurizing jig for pressing the material. The rigid mold has a shape corresponding to a shape of the preform. The pressurizing jig is adapted to apply pressures on the material at the different positions and the different timings.

Abstract: A method for hardening a preform into a composite part is provided. The method comprises aligning a layup mandrel carrying a preform for insertion into an autoclave having an inner surface that is complementary to a contour of the preform. The layup mandrel is then sealed into the autoclave.

Abstract: A tool for creating a self-stiffened panel, which comprises a support, a set of punches and a channel delimited between two punches, for each punch, a first securing arrangement including a slider that is able to move in translation on the support and at least one hook secured to the slider, and a second securing arrangement including at least one nose integral with the punch, and an actuating arrangement that moves the slider from a securing position in which each nose is located between the support and a hook, to a release position in which the hooks are offset with respect to the noses. With such a tool, each punch is held in position over its length, which ensures correct positioning during lay-up, even in the event of the tool being rotated.

Abstract: Methods for manufacturing RFID devices are provided with self-limiting heating features. Inducing current flow through the antenna of an RFID device (e.g., by exposing the antenna to a changing magnetic field) will increase heat of the RFID device, thereby curing/sintering elements of the RFID device (which may include curing an adhesive used to couple the antenna to an RFID chip) without applying external heat, which typically heats regions of the RFID device that were not intended to be heated (e.g., the substrate to which the antenna is secured). Inducing current flow through the antenna of an RFID device will reduce the resistance of the antenna, which has a heat-limiting effect that prevents overheating of the RFID device. Inducing current flow may also change the resonant frequency of the antenna, which may provide another heat-limiting effect.

Abstract: A composite material molding jig for molding a long member made of a fiber base material and a resin on a plate member includes: a first member that is made of a material having a thermal expansion coefficient equivalent to a thermal expansion coefficient of the long member, internally includes a space serving as a mold of the long member, and has an outer surface formed flat in a longitudinal direction; and a second member that is made of a material lighter than the material of the first member, internally includes a space shaped to contain the first member, and has an inner surface formed flat in the longitudinal direction, wherein the fiber base material is placed in the space inside the first member, and the first member is placed in the space inside the second member for molding the long member.

Abstract: Methods, systems, and robots for multi-layer prepreg composite sheet layup. The method includes obtaining a dataset including start and end point pairs of a mold of the 3D part. The method includes generating a layup sequence based on the dataset and generating multiple trajectories for one or more movements of the first robot or the first robot arm based on the layup sequence. The method includes causing a second robot or a second robot art to hold or grasp the prepreg layer or sheet a threshold distance above the mold or the 3D part. The method includes causing the first robot or the first robot arm to place or conform the prepreg layer or sheet to the mold of the 3D part.

Abstract: A tool for fabricating a control surface is disclosed. In various embodiments, the tool includes a first block defining a longitudinal direction running between a leading edge end and a trailing edge end; a first sidewall spaced a first lateral distance from the first block to form a first closeout channel running in the longitudinal direction between the first block and the first sidewall; and a second sidewall configured to form a second closeout channel running in the longitudinal direction, the second closeout channel disposed laterally opposite the tool from the first closeout channel.

Abstract: An apparatus according to the present exemplary embodiment is an apparatus that forms a composition on a substrate using a mold. The apparatus includes a gas supply unit that supplies gas to a periphery of a space sandwiched between the mold and the substrate, a deforming mechanism that deforms the mold, and a control unit that, in a state in which the gas supply unit increases a density of the gas in the periphery of the space sandwiched between the mold and the substrate, after the deforming mechanism deforms the mold in a concave shape with respect to the substrate and releases the mold from the deformation, brings the mold into contact with the composition on the substrate.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: Disclosed herein are methods for isolating a composite material from the environment, as well as the isolated composite material. Also disclosed herein are methods for shaping a composite material that include the use of isolated composite materials. For example, disclosed is a method for mechanical thermoforming of a composite material to form a shaped composite material.

Abstract: A method for manufacturing a fibre reinforced composite by means of a vacuum assisted resin transfer moulding, comprising the steps of placing a fibre material in a mould, placing a flow distribution medium onto the fibre material, and covering the fibre material (1) and the flow distribution medium with a vacuum foil for forming a closed mould cavity between the mould and the vacuum foil is described. It is characterised in using a flow distribution medium with a thickness depending on a pressure gradient over the vacuum foil.

Abstract: A method of filling a hydrogen-storage tank with a metal-organic framework (MOF) includes inserting MOF through an opening of the hydrogen-storage tank to at least partially fill an interior cavity of the tank with MOF. The method further includes positioning a compactor relative to the tank. The compactor includes a tamp configured to change shape between an insertion state in which the tamp is insertable through the opening and an expanded state in which the tamp is enlarged to be bigger than the opening. The method also includes inserting the tamp through the opening when the tamp is in the insertion state and switching the tamp from the insertion state to the expanded state. The method further includes compacting the MOF with the tamp.

Abstract: A press for pressing a component, such as a thermoplastic consolidation and/or forming press, has a first fixed part as a first pressing tool, a movable part as a second pressing tool for pressing a component together with the first pressing tool, and a second fixed part for applying a pressing force to the movable part, wherein the second fixed part and the movable part apply the pressing force generated via interaction between a magnetic field of a pressing magnet and a superconductor cooled below its step temperature.

Abstract: A gun holder supports a gun having an elongate barrel within a passenger vehicle having a foot space. The holder includes a floor mat configured to lay within the foot space of the passenger vehicle and a barrel support cup supported on the floor mat to locate the end of the barrel of the gun therein. More particularly the barrel support cup includes a perimeter wall protruding upwardly from the floor mat so as to define a hollow receptacle for partially receiving the end of the barrel of the gun therein such that the wall at least partially surrounds the end of the barrel of the gun within the barrel support cup and the barrel of the gun is at least partially restricted from sliding along an upper surface the mat in substantially all directions.

Abstract: A method of forming a composite article (22) comprises the steps of providing a tool (26) having a mold surface (24), providing a preform (62), and disposing the preform (62) on the mold surface (24). The method further comprises the steps of heating the mold surface (24) within a first period of time (Tt1), applying pressure to the preform (62) within a first period of time, and maintaining temperature of the mold surface (24) for a second period of time (Tt2). The method further comprises the steps of maintaining pressure for a second period of time, reducing pressure on the composite article (22), cooling the mold surface (24) within a third period of time (Tt3), and removing the composite article (22) from the mold surface (24). The total of Tt1+Tt2+Tt3 is generally no greater than about 30 minutes. A thermal system (20) comprising a heater-subsystem, and optionally, a chiller-subsystem, can be used to heat and cool the mold surface (24).

Abstract: A method for thermally processing and curing unprocessed components within a thermal processing and consolidation system which includes upper and lower chamber assemblies configured to couple to one another and a first tool, the method including positioning the first tool on the lower chamber assembly moving the lower chamber assembly relative to the upper chamber assembly and coupling the upper chamber assembly and the lower chamber assembly to form a plenum, thereby completely enclosing the first tool in the plenum, the plenum operable to maintain a pressurized and/or temperature controlled environment about the first tool, providing services to the first tool and the plenum via a service interface, and thermally processing and curing the first set of unprocessed components within the first tool wherein the services are supplied to the first tool as directed by a set of process parameters.

Abstract: A heat/vacuum molding system for molding a ski boot to a user's foot is provided. The system includes a heat source to heat an outer shell of the ski boot, a pliable plastic receptacle to receive the ski boot after the outer shell is heated by the heat source, and a vacuum system attached to the pliable plastic receptacle to create a negative pressure inside the pliable plastic receptacle to thereby collapse the pliable plastic receptacle to mold the ski boot to the user's foot.

Abstract: A method for creating a vacuum setup for processing a semi-finished fiber composite into a cured fiber composite component is provided. The semi-finished fiber composite is positioned on a molding surface of a tool so that a non-planar surface of the semi-finished fiber composite faces away from the molding surface, covering the non-planar surface of the semi-finished fiber composite by applying an air-tight film and sealing the film with respect to the molding surface of the tool. Application of the film is performed using a plunger formed from a flexible material and having a plunger surface on which the film is retained.

Abstract: A tool for curing a composite layup comprises a tool body having a surface adapted to support a composite layup thereon. The tool includes an integrated breather for allowing removal of air from the layup during curing.

Abstract: An in-situ double vacuum debulk (DVD) composite repair system designed to produce partially or fully cured autoclave-quality hot-bond composite repairs on contoured structures. The system provides vacuum pressure for hot bond repairs to be performed on flat and contoured structures using one set-up capable of debulking (partially curing) and then fully curing composite repairs on composite and metallic aircraft structures. The use of in-situ DVD also eliminates handling of the patch/adhesive when transferring from an off-aircraft DVD chamber to the repair site on the aircraft. This can increase the probability of successful repairs because the possibility of contaminating and misaligning the adhesive and repair patch are eliminated.

Abstract: A reusable vacuum bag for processing parts is made by encapsulating a generally rigid frame within a flexible diaphragm.

Abstract: A stabilizing mechanism for resisting relative movement of upper and lower laminates of a composite structure having a core comprises a lower grip strip and at least one upper grip strip. The lower grip strip may be mounted to a tool upon which the composite structure may be processed. The lower grip strip may include an outer surface having at least one engagement feature for engaging at least one of the upper and lower laminates which make up the composite structure. The upper grip strip may have opposing outer surfaces which may include at least one engagement feature for engaging the lower strip and at least one of the upper and lower laminates.

Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.