A structural component for an aircraft, spacecraft or rocket has a ply of fiber reinforced polymer, a first carbon nanotube mat; and a metallic layer, wherein the carbon nanotube mat and the metallic layer are arranged on the ply of fiber reinforced polymer to form a hybrid lightning strike protection layer. A component for manufacturing such a structural component, a method for manufacturing a component of this type, a method for manufacturing a structural component and an aircraft or spacecraft with such a structural component are described.

One embodiment is an apparatus including a mold configured to manufacture a composite structure at a heated temperature. The mold includes a first mold tool configured to mold a first portion of the composite structure, wherein the first mold tool comprises a plurality of strands of a fiber-reinforced thermoplastic material, wherein the fiber-reinforced thermoplastic material comprises a thermoplastic embedded with a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is aligned within each strand of the plurality of strands; and an anisotropic thermal expansion property, wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the first mold tool; and a second mold tool configured to mold a second portion of the composite structure.

A composite material for use as a deposition material in an additive manufacturing system comprises a polymer component, a filler component, and an extrudability component. The extrudability component is present in the composite material is an amount of from 0.05 wt % to 10 wt % based on the weight of the composite material, and can comprise polyhedral oligomeric silsesquioxane (POSS). The polymer component comprises a high temperature polymer such as an engineering polymer or a high performance polymer. The filler component comprises at least one of a conductive component and a strengthening component. In some cases, the conductive component is present in an amount such that the composite material is formed as one of an electrostatic discharge (ESD) material and an EMI/EMC shielding material. The composite material can be deposited in a liquid state on a substrate using an additive manufacturing system, to produce a three-dimensional object.

A structural component, in particular for an aircraft, spacecraft or rocket, has a ply of fiber reinforced polymer; a first carbon nanotube mat; and a metallic layer, wherein the carbon nanotube mat and the metallic layer are arranged on the ply of fiber reinforced polymer to form a hybrid lightning strike protection layer. A component for manufacturing such a structural component, a method for manufacturing a component of this type, a method for manufacturing a structural component and an aircraft or spacecraft with such a structural component are described.

A honeycomb structure having a core made up of a plurality of corrugated sheets which are superposed and adhesively bonded together is described. The corrugated sheets are made from a thermally insulating material. Bear filaments are made up of thermally conductive filaments. The honeycomb structure can be used when the ambient temperature exceeds, for example, 120° C.

A honeycomb structure having a core made up of a plurality of corrugated sheets which are superposed and adhesively bonded together is described. The corrugated sheets are made from a thermally insulating material. Bear filaments are made up of thermally conductive filaments. The honeycomb structure can be used when the ambient temperature exceeds, for example, 120° C.

A method for producing a shell for luggage, comprising: a) producing a preform comprising a structure and including a reinforcement, the structure, which comprises a main zone, two longitudinal zones and two transverse zones, having loops successively forming rows of loops, the rows of loops being connected to each other, and b) placing the preform on a punch, c) impregnating the reinforcement of the preform with a matrix material in order to produce a shell comprising a body, the body being made of a composite material and comprising the matrix and the reinforcement, and the body having a main wall, two longitudinal walls and two transverse walls.

A method for producing a shell for luggage, comprising: a) producing a preform comprising a structure and including a reinforcement, the structure, which comprises a main zone, two longitudinal zones and two transverse zones, having loops successively forming rows of loops, the rows of loops being connected to each other, and b) placing the preform on a punch, c) impregnating the reinforcement of the preform with a matrix material in order to produce a shell comprising a body, the body being made of a composite material and comprising the matrix and the reinforcement, and the body having a main wall, two longitudinal walls and two transverse walls.

A method of manufacturing a polymer composite having an embedded functionality includes the following steps: providing a dry non-conductive fiber fabric having a nominal weight from 25-600 g/m.sup.2; selecting a paste having viscosity below 600 Pa-s, the paste being a conductive paste, dielectric paste and/or a sensing paste; and applying the selected paste on the dry non-conductive fiber woven fabric by either screen-printing or micro-dispensing, thus making a printed functionality. The method further includes the step of forming a laminate having the dry non-conductive fiber woven fabric having the printed functionality and at least one additional fabric or core; and obtaining a polymer composite from the laminate.

A system for making highly contoured composite stringers, including a flexible stringer assembly to support an uncured composite stringer; and a contoured mandrel to contour the uncured composite stringer into a highly contoured shape, wherein the contoured mandrel comprises one or more curvatures with a radius of 100 inches or less along at least one of an x, y, or z axis.