A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.

A method for repairing a crack in a structure includes mounting a manifold to the structure around the crack. The structure has a nonplanar surface contour that surrounds the crack. The manifold has a base portion, a cover portion, and a plug. The base portion has a grip surface configured to conform to the nonplanar surface contour of the structure. The cover portion is connected to the base portion, and has an injection port and a vent port in fluid communication with a channel aligned to the crack. The injection port transfers a bonding material into and out of the channel. The plug closes and opens the vent port. The method includes filling the channel with the bonding material to direct the bonding material into the crack, and draining the bonding material from the manifold.

An automatic machine for repairing plastic sheets having incorporated in a support structure (3): a rotary head (4), with several work stations with cutting device (5) for cutting the edge of a sheet (2), donor pellet supply device (6, 7), welding device (8) for welding the donor pellet, and pressing device (9) for pressing the weld thus made; an outer bench (10) for situating the sheet (2) to be repaired on same; donor pellet fastening device (11); sheet fastening device for holding the sheet (2); andoperation control device connected to a programmable logic controller.

An automatic machine for repairing plastic sheets having incorporated in a support structure (3): a rotary head (4), with several work stations with cutting device (5) for cutting the edge of a sheet (2), donor pellet supply device (6, 7), welding device (8) for welding the donor pellet, and pressing device (9) for pressing the weld thus made; an outer bench (10) for situating the sheet (2) to be repaired on same; donor pellet fastening device (11); sheet fastening device for holding the sheet (2); andoperation control device connected to a programmable logic controller.

A method for repairing a defect in a vehicle exterior body surface is provided that includes a scan data set being generated that corresponds to the dimensional surface boundaries of the defect. A manufacturing data set is created for an object at least in part complementary to the defect from the scan data. The object is formed from the manufacturing data set with a layered manufacturing device. The object is joined to the defect to repair the vehicle exterior body surface. An object is also provided formed of a thermoplastic or a UV cured polymer with a shape that is at least at least in part complementary to a defect vehicle exterior body surface. The object having a void therein with the shape configured to receive an insert or a fastener therein.

Method for repairing plastic dividers (1), having longitudinal internal cavities (100), by following the steps of: identifying and extracting the damaged areas to be repaired (2), some gaps (4) being defined, preparing inserts (5) with a shape matching the gaps (4), and attaching by heat welds (8) the inserts (5) in the gaps (4); wherein the damaged areas to be repaired are extracted by cuts (3) with a curved path, and wherein in the step of preparing the inserts (5), the inserts are machined with an outer edge (50) aligned with the edges (10) of the divider (1), and an inner edge (51) parallel to the curved path of the cut (3), there being defined between the cut (3) made in the divider (1) and the inner edge (51) of the insert (5) a filling space (7) for filling with filler material (8).

Method for repairing plastic dividers (1), having longitudinal internal cavities (100), by following the steps of: identifying and extracting the damaged areas to be repaired (2), some gaps (4) being defined, preparing inserts (5) with a shape matching the gaps (4), and attaching by heat welds (8) the inserts (5) in the gaps (4); wherein the damaged areas to be repaired are extracted by cuts (3) with a curved path, and wherein in the step of preparing the inserts (5), the inserts are machined with an outer edge (50) aligned with the edges (10) of the divider (1), and an inner edge (51) parallel to the curved path of the cut (3), there being defined between the cut (3) made in the divider (1) and the inner edge (51) of the insert (5) a filling space (7) for filling with filler material (8).

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

A method of repairing a composite blade. The composite blade includes a metal work bonded to a composite part through an adhesive layer. The method includes determining a locally damaged portion of the metal work, and removing a bullet portion corresponding to the locally damaged portion. The method further includes detaching, debonding, and removing a first wing portion from the composite part to obtain a first exposed surface portion. The method further includes detaching, debonding, and removing a second wing portion from the composite part to obtain a second exposed surface portion. The method further includes reconditioning the first and second exposed surface portions to obtain first and second reconditioned surface portions, respectively, and applying first and second adhesive layers to the first and second reconditioned surface portions respectively. The method further includes bonding a metal work patch to the first and second adhesive layers.