Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Described herein are methods and systems for forming composite stringer assemblies or, more specifically, for shaping composite charges while forming these stringer assemblies. A system comprises a bladder, having a bladder core, and a bladder skin. The bladder core is formed from foam. The bladder skin is formed from an elastic material and encloses the bladder core. When a composite stringer assembly is formed, the bladder is positioned over a charge base. The charge base later becomes a stringer base, such as a fuselage section or a wing skin. A charge hat is then positioned over the bladder and is conformed to the bladder. A combination of the bladder skin and the bladder core provides support during this forming operation and later while the stringer assembly is cured. In some examples, the bladder core is collapsible for the removal of the bladder from the cavity of the stringer assembly.

Embodiments herein include extruded articles, building components and methods of making the same. In an embodiment, an extruded article is included. The extruded article can include a body member including a first portion comprising a first composition, the first composition comprising a polymer resin. The extruded body member can also include a second portion comprising a second composition different than the first composition. The second composition can include a polymer resin, fibers, and at least one component selected from the group consisting of at least 1% by weight particles and at least 5 phr impact modifier. Other embodiments are also included herein.

A thin plate molding material includes a resin composition containing a resin component and a filling material, and a reinforced fiber with a predetermined fiber length. The content ratio of the reinforced fiber is a predetermined ratio. The mixing ratio of the resin component is a predetermined ratio.

A composite sandwich panel comprises a first composite skin, a second composite skin, a hollow cell core between the first composite skin and the second composite skin, and a first over-crush edge region with a first edge. The first edge has a first thickness at least 40% less than a nominal thickness of the composite sandwich panel. The first over-crush edge region has a length of at least 0.25 inches over which a thickness of the composite sandwich panel decreases.

A method of fabricating a part out of composite material, includes forming a fiber texture from refractory fibers; placing the texture in a mold having an impregnation chamber including in its bottom portion a part made of porous material, the impregnation chamber being closed in its top portion by a deformable impermeable diaphragm separating the impregnation chamber from a compacting chamber; injecting a slip containing a powder of refractory particles into the impregnation chamber; injecting a compression fluid into the compacting chamber, to force the slip to pass through the texture; draining the liquid of the slip via the porous material part, while retaining the powder of refractory particles inside the texture so as to obtain a fiber preform filled with refractory particles; drying the fiber preform; unmolding the preform; and sintering the refractory particles present in the preform in order to form a refractory matrix in the preform.

A method of fabricating a blade. The blade comprises subassemblies made of thermoplastic composite materials, each subassembly comprising an internal arrangement and at least one external arrangement, each internal arrangement comprising a stack of intermediate layers comprising reinforcing fibers impregnated with a semicrystalline thermoplastic matrix, each external arrangement comprising at least one surface layer comprising reinforcing fibers impregnated with an alloy of a semicrystalline thermoplastic polymer and of an amorphous thermoplastic polymer. An assembly film comprising an amorphous thermoplastic material and a ferromagnetic member is interposed between two surface layers of two distinct subassemblies that are to be assembled together by a method of local heating by induction.

A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130° C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180° C. and the sheath contains a polymer having a melting temperature less than about 180 ° C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

Methods for forming vascular components include providing a composite sacrificial body comprising a first sacrificial material having an outer surface and a second sacrificial material applied to at least a portion of the outer surface, molding a solid substrate around the composite sacrificial body, removing the first sacrificial material by deflagration such that at least a portion of the second sacrificial material remains in the same orientation relative to the substrate as originally molded, and subsequently removing the second sacrificial material by a non-deflagration process to form a vascular component. The second sacrificial material can include a phase change material, a syntactic foam including hollow beads bound together with a polymeric binder or a sintered aggregation of hollow beads, a polymeric foam, a water-soluble resin, or an aerogel. The non-deflagration process can include mechanical pulverization, contacting the second sacrificial material with a solvent or chemical etching agent.