In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a cavity with a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the cavity. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity.

A method may comprise applying a first adhesive to a cavity of a bond panel, the cavity defined by a raised body portion of the bond panel, inserting an acoustic insert assembly in the cavity, the acoustic insert assembly being secured in the cavity by the first adhesive, and securing edges of the acoustic insert assembly to the raised body portion of the bond panel with a second adhesive to create a seamless interface between the edges and the raised body portion.

A foam-based expansion joint seal system packaging which facilitates transport and reduces the need for internal splices.

A vehicle body may have a skeleton formed by a plurality of overlapping layers bonded to each other. Each of the plurality of overlapping layers may be fabricated from a continuous fiber coated with a matrix material. A trajectory of the continuous fiber may be different between adjacent layers of the plurality of overlapping layers.

A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.

A method for fabricating a composite structure is provided. A first number of layers of composite material is laid up to form a first set of stiffeners. A second number of layers of composite material is laid up to form a panel. The first set of stiffeners is associated with a first side of the panel. A pre-cured composite strip is positioned on a second side of the panel, opposite the first side. A third number of layers of composite material is laid up on the second side of the panel to form a second set of stiffeners running perpendicular to the first set of stiffeners. The pre-cured composite lies at an intersection between one of the first set of stiffeners and one of the second set of stiffeners. All the layers of composite material are co-cured to form the composite structure.

A vehicle body may have an internal skeleton, and a skin formed over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. At least one of the plurality of continuous fibers is in tension and has differing levels of tension along its length.

An impregnation system and a method for impregnating a textile fabric for composite components are described. A matrix 2 can be applied to a textile fabric 1 in such a way that the matrix 2 penetrates it at least partially and/or at least on one side. A first and a second endless belt 1 each designed as a belt loop are provided for the impregnation system. Between the first 4 and the second belt loop 5, the textile fabric 1 can guided on the mutually facing surfaces 6 of the belt loops and can be impregnated there. The deflection rollers 7 are provided in the respective belt loop 4, 5 of the respective endless belts at the deflection areas, with at least one roller being adjustable in the direction of the mutually facing surfaces 6 of the belt loops 4, 5. By adjusting the rollers 8 in the y direction, the wrap angle and thus the pressure exerted on the textile fabric during impregnation is controlled.

A vehicle body may have an internal skeleton, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers encased within the matrix material. The plurality of continuous fibers may include at least one electrically conductive wire interwoven with others of the plurality of continuous fibers. The at least one electrically conductive wire may be configured to function as at least one of a heater and a strain gauge.

A vehicle body may have an internal skeleton forming a wing shape and a fuselage shape, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers at least partially coated with the matrix material. The plurality of continuous fibers may extend from the wing shape over the fuselage shape.