A forming device, system, and method for continuous forming of a semi-finished fiber product. The semi-finished fiber product is supported flatly from a first side and is at least locally restricted in its freedom of movement, for example pressed on and/or guided, on another side opposite the first side. The further restriction occurs in relation to a guiding area at at least one constant location or region past which the semi-finished fiber product is guided. Shaping tools and guiding areas defined thereby are used for support, and hold-down devices and their contact surfaces are used for further restriction. The further restriction is carried out transversely to a feed motion direction of the semi-finished fiber product through the forming device. The further restriction and the flat guidance serve to reduce formation of undulations and folds.

In a preform shaping method, a fiber stack that has a plurality of fiber layers by stacking sheet-form fibrous components is manufactured and a preform that has a configuration in which a first surface and a second surface one or both of which are curved surfaces are coupled is manufactured by bending the sheet-form fibrous components after or while stacking the sheet-form fibrous components. A first sheet-form fibrous component and a second sheet-form fibrous component fiber length directions of which are set to such different directions before a bending process as to be target fiber length directions after the bending process and which form the first surface and the second surface, respectively, after the bending process are disposed in order to form at least one fiber layer of the plurality of fiber layers.

According to one implementation, a preform shaping method for producing a preform having a web, a flange, and a chamfered portion includes: pressing a first portion of a laminated body of fiber sheets by sandwiching the first portion between a first mold and a second mold; and pressing a second portion of the laminated body of the fiber sheets after pressing the first portion. The first portion corresponds to the web. The second portion corresponds to the flange. The first mold fits a surface in one side of the web, an inner surface of the chamfered portion and a surface in one side of the flange. The second mold fits a surface in the other side of the web. The second portion is pressed by sandwiching the second portion between the first mold and a third mold.

In one aspect of the present subject matter, a method of forming a linear panel includes drawing a multi-layer panel material assembly having differing inner and outer material layers along a processing path. The method also includes heating the panel material assembly. In addition, the method includes forming the heated panel material assembly into a desired shape as the assembly is drawn along the processing path. Additionally, in another aspect of the present subject matter, a linear panel includes a body formed from a multi-layer panel material assembly having differing inner and outer material layers.

A trim piece for sealing a work surface including a body having a first side, a second side, and a span disposed between the first side and the second side, wherein the first side and the second side are joined at a junction defining an angle between the first side and the second side of between 80 degrees and 100 degrees, a topcap is affixed to the span of the body, wherein the topcap includes a left side having a first wing and a right side having a second wing, an adhesive is bonded to the first side of the body and an aperture is disposed within the body.

The composite pultruded products either in “I” profile or “Plate” profile of higher cross sectional area where said products consisting essentially synthetic polyester felts as core impregnated with a resin system comprises of at least one resin, curing system comprising a curing agent and an accelerator, a filler, a thinner, pigment or any other additives; encapsulated between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with said resin system are provided. In another composite pultruded products either in “I” profile or “Plate” profile of higher cross sectional area where said products consisting of plank of short fibers bagasse premixed with the said resin system as core is enclosed between the synthetic polyester felts impregnated with the resin system which is further enclosed between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with the resin system. The system and method for the preparation of said composite pultruded products are also illustrated herein. These products lead to a significant reduction in weight and reduction in density with higher stiffness and bending strength. The present composite products are encapsulated by fabrics in the peripheral area bringing more integrity uniformity of synthetic polyester felt materials. This leads to a significant cost reduction without sacrificing much tensile strength.

A structural web having a fabric material element 20 that has been stitched or embroidered with a reinforcing fiber 24, the fabric material element 20 defining a peripheral region 28a, 30a, and the reinforcing fiber 24 extending onto the peripheral region 28a,30a, the fabric material element 20 and reinforcing fiber 24 being bent to take on a non-planar form with the peripheral region 28a, 30a angled to a main plane of the element 20 to define an engagement face for cooperation with another component 12, 14, and upon which at least part of the reinforcing fiber 24 is located.

There is provided a forming system for forming a contoured composite structure having a complex curved configuration. The forming system includes a receiving station having a receiving assembly to receive a composite charge to be formed. The forming system includes a forming station having a forming assembly. The forming assembly includes a gantry assembly, an upper die assembly movably coupled to the gantry assembly, a lower die assembly coupled to a floor support beam positioned between the gantry assembly, and one or more pick-and-place devices movably coupled to the gantry assembly. The upper die assembly is separate from, and independently movable with respect to, the lower die assembly. The pick-and-place device(s) are designed to move the composite charge, and the contoured composite structure. The forming system includes a tray station having a tray assembly designed to receive the contoured composite structure from the forming station.

A vehicle crossmember is made from continuous fiber-reinforced polymeric material without the need for metallic structural reinforcements. The crossmember includes more than one fiber-reinforced material composition, including different amounts and/or types of fiber reinforcements along different lengthwise portions of a crossbar of the crossmember. Attachment points and stiffening ribs can be overmolded onto surfaces of the crossbar before assembling two halves of the crossbar together to form the crossmember.

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.