Lightweight, structurally reinforced thermoplastic objects comprising at least one reinforcement zone are manufactured by providing a heatable rigid forming chamber with a chamber volume. At a temperature below the thermoplastic softening temperature, the chamber is loaded with a plurality of thermoplastic lofting bodies and a plurality of thermoplastic reinforcement bodies wherein the lofting bodies are heat-loftable bodies comprising a thermoplastic matrix containing an elastically compressed assembly of reinforcement fibers embedded therein, lofty non-woven bodies comprising an elastically compressible assembly of reinforcement fibers and thermoplastic fibers. Upon closing the chamber, lofting bodies of lofty non-wovens are elastically compressed, producing an internal pressure. After heating the chamber above softening temperature, reinforcement bodies and lofting bodies are ow thermoplastically formable, and lofting bodies configured as heat-loftable bodies produce a second internal pressure. After a predetermined processing time, the chamber is cooled yielding a structurally reinforced object.

Skin-bonded threaded inserts may be installed within a sandwich panel by curing the insert in place as the sandwich panel is cured. Skin-bonded threaded inserts may include a collar that is transitioned between a raised position and a compressed position during installation of the skin-bonded threaded insert in the sandwich panel, due to compression of the sandwich panel during curing. Skin-bonded threaded inserts may include one or more flanges that engage one or more skins of the sandwich panel. Such flanges may be positioned between two skins, or between the core and a skin of the sandwich panel to secure the sandwich panel in place within the sandwich panel. Skin-bonded threaded inserts may be positioned within a sandwich panel without the use of potting compound and may engage with the skins of the sandwich panel, rather than relying on adherence to the core for sufficient pull-out and shear strength.

A composite part is provided and includes a component, a first set of first composite plies with finite lengths and a second set of second composite plies with finite lengths. A respective end of each of the first composite plies is wrapped around the component in a clockwise wrapping direction and includes first fibers. A respective end of each of the second composite plies is wrapped around the component in a counter-clockwise wrapping direction and includes second fibers.

A tube assembly including a cross-linked polyethylene tube having a radial projection and a coupler, and a method for forming the tube assembly. A forming assembly is configured to dispose the radial projection of the cross-linked polyethylene tube through the coupler after the completion of the cross-linking process.

A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having an amorphous thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the amorphous thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.

A method of production of a frac plug is disclosed comprising providing a blank defining an interior of the frac plug, placing a glass material around the blank such that a fiber reinforcement within the glass material is off axis to a longitudinal axis of the frac plug and wherein the placing forms a glass material blank, removing the blank from the glass material blank and performing at least one mechanical processing of an exterior of the glass material blank.

A method of production of a frac plug is disclosed comprising providing a blank defining an interior of the frac plug, placing a glass material around the blank such that a fiber reinforcement within the glass material is off axis to a longitudinal axis of the frac plug and wherein the placing forms a glass material blank, removing the blank from the glass material blank and performing at least one mechanical processing of an exterior of the glass material blank.

A structure-lining apparatus for lining one or more surfaces of a structure formed from curable material cast in a form. The apparatus comprises a plurality of panels. The panels are connected at their respective edges in an edge-to-edge connection to provide a structure-lining surface. A plurality of anchoring components project from the panels into the liquid material during fabrication of the structure. The anchoring components each comprise one or more anchoring features which are encased in the material as the material solidifies to thereby bond the anchoring components to the structure. The plurality of anchoring components comprises one or more connector-type anchoring components for connecting to corresponding connector-type anchoring components on adjacent edges of a corresponding edge-adjacent panel to connect the edge-adjacent panels in an edge-adjacent relationship. The apparatus comprises one or more breakaway components on at least one of the plurality of panels.

A structure-lining apparatus for lining one or more surfaces of a structure formed from curable material cast in a form. The apparatus comprises a plurality of panels. The panels are connected at their respective edges in an edge-to-edge connection to provide a structure-lining surface. A plurality of anchoring components project from the panels into the liquid material during fabrication of the structure. The anchoring components each comprise one or more anchoring features which are encased in the material as the material solidifies to thereby bond the anchoring components to the structure. The plurality of anchoring components comprises one or more connector-type anchoring components for connecting to corresponding connector-type anchoring components on adjacent edges of a corresponding edge-adjacent panel to connect the edge-adjacent panels in an edge-adjacent relationship. The apparatus comprises one or more breakaway components on at least one of the plurality of panels.

A manufacturing method contemplates performing vacuum-assisted resin infusion to enclose an elongated core within a cured composite laminate without employing a mold. Not relying upon an external mold enables the process to be efficiently performed for core shapes that are manufactured in low volumes. Typical resin infusion processes utilize flow media that induces bag bridging during vacuum draw in order to provide gaps facilitating resin flow. However, popular flow media also tends to impart directional aggregate forces during vacuum draw, which forces can deform the core since no mold is being used. To avoid unequal and non-dispersed directional forces from deforming the elongated core, a flow media is employed that is configured to disperse and/or reduce such forces. Some such flow media may be knitted so as to allow overlapping strands to slide over one another. Other flow media may ensure that strands are interleaved so that no one strand or group of strands is disposed outwardly of other strands along a substantial length of the strands, thus dispersing bag bridging forces in several directions and avoiding directional aggregate forces. However, such flow media may have inhibited resin flow relative to popular high-flow flow media, and thus new strategies have been developed to ensure appropriate wetting of fibrous reinforcement. An adjustable brace can also be employed to restrain the elongated core from deflecting during application of vacuum and/or resin infusion.