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 honeycomb core includes a honeycomb substrate comprised of a number of sheets. A number of traces are printed onto the sheets of the honeycomb substrate. A number of integrated electronic devices are disposed within the honeycomb substrate. The integrated electronic devices are electrically coupled to the traces.

A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets by creating a resin affinity portion and a resin repellant portion on the sheets. The resin affinity portion and the resin repellant portion forms the venting pathways. A honeycomb substrate is then formed from the sheets.

A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets to form the venting pathways. A honeycomb substrate is then formed from the sheets.

A three-dimensional structure includes a plate and a three-dimensional component disposed on the plate. The three-dimensional component contains at least one first structure and at least one second structure. The first structure is an auxetic structure, and the second structure is different from the first structure. The at least one first structure and the at least one second structure are provided layer by layer along a thickness direction of the plate on the plate.

A three-dimensional structure according to the present invention is a three-dimensional structure defined by X, Y, and Z directions, including: a body portion in which a plurality of through holes extending in the X direction are disposed in alignment in at least one of the Y and Z directions; and a partition portion that is provided in at least one of the through holes and that partitions the through hole in at least one location in an axial direction of the through hole, wherein the three-dimensional structure is formed by a rubber composition.

A method of manufacturing a sandwich structure having an open cellular core and a fluid-tight seal surrounding the core includes coupling a mold to a first facesheet to define a reservoir. The method also includes irradiating a volume of photo-monomer in the reservoir with a series of vertical collimated light beams to form a cured, solid polymer border extending around a periphery of the first facesheet. The method also includes irradiating a remaining volume of photo-monomer in the reservoir with a series of collimated light beams to form an ordered three-dimensional polymer microstructure core defined by a plurality of interconnected polymer optical waveguides coupled to the first facesheet and surrounded by the cured, solid polymer border. The method further includes coupling a second facesheet to the ordered three-dimensional microstructure core and the cured, solid polymer border to form the sandwich structure.

A manufacturing method of a honeycomb structure forming die includes a linear slit forming step of forming, in a kneaded material discharging surface of a die substrate, a plurality of linear slits which are straight from one end to the other end on the kneaded material discharging surface, a slit sealing material disposing step of disposing a slit sealing material in parts of the plurality of linear slits, and a back hole forming step of forming back holes to introduce a kneaded material, in a kneaded material introducing surface of the die substrate which is present on a side opposite to the kneaded material discharging surface.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

An airfoil member can have a root end, a tip end, a leading edge, and a trailing edge. The airfoil member can include an upper skin, a lower skin, and a composite core member having a plurality of cells, an upper surface network of the cells can be bonded to the upper skin, a lower surface network of the cells can be bonded to the lower skin. The composite core can have a septum layer embedded in the cells that form the composite core, the septum layer being configured to provide tailored characteristics of the airfoil member.