A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

A thermally conductive sheet having a binder resin, a first thermally conductive filler, and a second thermally conductive filler, wherein the first thermally conductive filler and the second thermally conductive filler are dispersed in the binder resin, and the specific permittivity and the thermal conductivity are different in the thickness direction B and the surface direction A of the thermally conductive sheet. A thermally conductive sheet includes step A of preparing a resin composition for forming a thermally conductive sheet by dispersing a first thermally conductive filler and a second thermally conductive filler in a binder resin, step B of forming a molded block from the resin composition for forming a thermally conductive sheet, and step C of slicing the molded block into a sheet and obtaining a thermally conductive sheet having different relative permittivity and thermal conductivity in the thickness direction and the surface direction.

A stiffened part formed from at least two members of thermoset composite material including at least one body of a first structure and optionally a second structure. A manufacturing method includes: forming a fibre preform and impregnating each body of the first structure with thermosetting resin or forming a pre-impregnated fibre preform to obtain a body formed from uncured thermosetting composite material supported by a mandrel; optionally partially or fully polymerising at least one body supported by a mandrel; optionally, providing the second structure formed from uncured, partially uncured or fully uncured thermosetting composite material; optionally, depositing a layer of uncured thermosetting adhesive on an area where a fully cured member makes contact with another member of the part; joining the members, each member being juxtaposed with; or stacked upon, at least one other member; fully curing the assembly by heat treatment; removing the mandrel from each fully cured body.

Structure intended to stiffen a component made of thermosetting composite material by being fitted to at least one of its surfaces, including: at least one longitudinal body, with first and second longitudinal edge faces on opposite sides, and first and second lateral faces on opposite sides; at least one base including at least one mounting base, each base having a plate and first and second tongues which delimit, with the plate, a housing for at least one body, the first and second tongues extending from a main face of the plate and being pressed respectively against the first and second lateral faces of the body. Each mounting base has a plate which is secured to the first longitudinal edge face of a body and which is intended to be pressed against the surface of the component to be stiffened. Each body and each base are made of thermosetting composite material.

Systems and methods of curing a thermoset composite (TSC) to a target state of cure (SOC) are disclosed herein. The methods include heating the thermoset composite to greater than a threshold temperature. During the heating, the methods further include monitoring an actual temperature of the thermoset composite, determining a maximum temperature achieved by the thermoset composite, and determining an elapsed time that the actual temperature of the thermoset composite is greater than the threshold temperature. The methods further include ceasing the heating based, at least in part, on the maximum temperature of the TSC and the elapsed time. The systems include a heating assembly, a support mandrel, a thermoset composite, a temperature detector, and a controller programmed to perform the methods.

A method and apparatus for forming a 3D article. According to the method, a composite filament material is formed from a UV curable material, a thermoset polymer material and at least one of filaments or fibers. After the composite is formed, the filament is dispensed to form the 3D article. Dispense is typically through a nozzle or other orifice that delivers the composite filament material as a bead of material. As the composite is dispensed, at least a portion of the composite material is exposed to UV radiation thereby curing a portion of the dispensed composite filament. The UV radiation is provided by a light source than can target discrete portions of the dispensed composite filament. For this purpose, the UV radiation source can be a light source integrated with the nozzle or a steered light source. As the composite filament is dispensed, UV radiation is directed onto the composite filament. If a steered light source is used, the composite filament is dispensed and light from the steered UV radiation source is directed to targeted regions of the composite filament, introducing cured zones or regions into the composite filament.

A method for manufacturing a luggage formed by composite material includes the steps: A) using a vacuum molding method to make a thermoplastic sheet into a shell; B) placing the shell in an inner cavity mold area of a heating mold to correspond the outer surface of the shell to the inner wall surface of the inner cavity mold area; C) setting the outer surface of the thermosetting carbon fiber plastic layer on the inner surface of the shell ; D) setting the reinforcing layer on the inner surface of the thermosetting carbon fiber plastic layer at the location corresponding to the corner of the shell; and E) placing an airbag in the receiving area of the shell and inflating the airbag to support the inner surface of the thermosetting carbon fiber plastic layer and the reinforcing layer.

A resin sheet according to the present disclosure includes an uncured product or semi-cured product of a thermosetting resin composition. A melt viscosity of the resin sheet is equal to or greater than 10 Pa.Math.s and equal to or less than 2000 Pa.Math.s when measured using a Koka flow tester under a measuring condition including 130° C. and 1 MPa and is equal to or greater than 6 Pa.Math.s and equal to or less than 1200 Pa.Math.s when measured using the Koka flow tester under a measuring condition including 130° C. and 4 MPa.

A composite material molded product has a hollow portion, a bent portion, or a curved portion in a transverse section thereof. When the composite material molded product has, for example, a bent portion, a surface on an inside of the bent portion is a pressed surface. A mold includes a pressing body that is thermally expandable and has an outer surface shape corresponding to a shape of a pressed surface, and a mold main body including a cavity accommodating the laminate and the pressing body inside, the cavity including an inner surface shape corresponding to a shape other than the pressed surface. The cavity is sealed in a state that the pressing body is disposed in the cavity. The laminate is accommodated in a molding space formed between an inner surface of the cavity and an outer surface of the pressing body.

Methods of making multilayer systems comprising a sealant layer by extruding a coreactive sealant composition are disclosed. The methods can be used to fabricate multilayer systems in which individual layers have different cured properties. Individual layers can also have an inhomogeneous concentration of one or more constituents within a layer. The multilayer systems can be made using three-dimensional printing that facilitate the use of a wide range of coreactive compositions.