Methods for forming composite components with sealed bi-material interfaces include applying a sacrificial material to a surface of a substrate, over-molding the substrate and the sacrificial material with an over-molding material such that the over-molding material covers at least a portion of the sacrificial material and at least one surface of the substrate, removing the sacrificial material by deflagration to form a composite component with a channel between the substrate and the over-molding material, introducing an uncured sealant into the channel, and curing the sealant to form a sealed composite component. The method can further include removing a portion of the sealant prior to the sealant fully curing. The sealed composite component can include a passage, encircled by the channel, extending between the substrate and the over-molding material. The substrate can be a metal, a polymer, a polymer composite, a ceramic, or a continuous fiber composite material.

Methods for forming composite components with sealed bi-material interfaces include applying a sacrificial material to a surface of a substrate, over-molding the substrate and the sacrificial material with an over-molding material such that the over-molding material covers at least a portion of the sacrificial material and at least one surface of the substrate, removing the sacrificial material by deflagration to form a composite component with a channel between the substrate and the over-molding material, introducing an uncured sealant into the channel, and curing the sealant to form a sealed composite component. The method can further include removing a portion of the sealant prior to the sealant fully curing. The sealed composite component can include a passage, encircled by the channel, extending between the substrate and the over-molding material. The substrate can be a metal, a polymer, a polymer composite, a ceramic, or a continuous fiber composite material.

A method of forming set pin hole of an insulated carbine hook includes: providing a core material with a perforation and a recess; putting the core material in a mold cavity of a mold including a movable pin protruding from an inner surface of the mold cavity, which is at an opening of the perforation; filling insulated material between an outer surface of the core material and the inner surface, and in the perforation and recess; forming an insulated layer on the outer surface and in the perforation and recess to obtain an insulated intermediate having a notch at the opening; aiming a removal tool at the notch; removing the insulated material at the other opening of and in the perforation, and at an opening of and in the recess to form the set pin hole, which makes the manufacturing a main body of the insulated carbine hook easy.

A curable aqueous composition is disclosed comprising a carbohydrate, a crosslinking agent, and an amine base, wherein the curable aqueous composition has a pH adjusted by the amine base. Further disclosed is a method of forming a curable aqueous solution.

A curable aqueous composition is disclosed comprising a carbohydrate, a crosslinking agent, and an amine base, wherein the curable aqueous composition has a pH adjusted by the amine base. Further disclosed is a method of forming a curable aqueous solution.

Certain embodiments described herein are directed to articles that provide less sag. In some examples, the articles can include a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer, and a frim disposed on the fiber reinforced polymer core layer. In certain examples, the frim comprises a film coupled to a scrim comprising an effective basis weight to prevent substantial sag of the article, e.g., during a forming operation.

The present disclosure describes lug clusters for composite tubes and methods for making such lug clusters. Lug clusters of the present disclosure may include a first side, a second side, and a saddle. The saddle may be placed in adjacent contact with a tube and a filament may be wound around the lug cluster and tube. The wound lug cluster and tube may be resin transfer molded. Machining may follow to remove material and finalize the shape of the lug cluster and/or tube. Thus, a lug cluster may be attached to a composite tube.

A three-dimensional electronic, biological, chemical, thermal management, and/or electromechanical apparatus can be configured by depositing one or more layers of a three-dimensional structure on a substrate. Such a three-dimensional structure can include one or more internal cavities using an additive manufacturing system enhanced with a range of secondary embedding processes. The three-dimensional structure can be further configured with structural integrated metal objects spanning the internal cavities (possibly filled with air or even evacuated) of the three-dimensional structure for enhanced electromagnetic properties.

The present invention provides a self-adhesive prepreg which is characterized by comprising: a base prepreg that is composed of reinforcing fibers and a thermosetting resin composition (I), some or all of which is impregnated into a reinforcing fiber layer that is formed of the reinforcing fibers; an adhesive layer that is composed of a nonwoven fabric which is laminated on at least one surface of the base prepreg so as to be integrated with the base prepreg and a thermosetting resin composition (II) which is laminated on the surface of the nonwoven fabric so as to be integrated with the nonwoven fabric.

A hybrid structure includes a frame member with at least three walls, forming a channel having a convex portion where two walls meet. A concave deformation is present in at least one convex portion, wherein the concave deformation extends into the channel and has open ends forming an opening through the convex portion. A plastic reinforcement member is present in the channel, wherein a portion of the reinforcement member extends into the opening and on the concave deformation.