An injection-molding machine (10) has a static mold (14), a mold shaft (15) inserted into an inner space (14a) of the static mold (14) and having a central axis (15a), a rotation mechanism (17) which rotates the mold shaft (15) around the central axis (15a), and a raw material injection mechanism (1) which injects as a raw material, a composite material containing resin and fiber into the inner space (14a) of the static mold (14). The raw material is injected from a tip section of the mold shaft (15) into the inner space (14a) of the static mold (14) along the mold shaft (15). A technique of properly controlling the fiber orientation in the injection molding of the composite material part is provided.

A vane includes a fiber reinforcement having a three-dimensional weaving densified by a matrix, the fiber reinforcement including in a single woven part a root portion and an airfoil portion extending along a longitudinal direction between the root portion and a vane tip portion and along a transverse direction between a leading edge portion and a trailing edge portion. The airfoil portion includes first and second extrados and intrados faces. The fiber reinforcement includes a non-interlinking forming a housing inside the fiber reinforcement, a conformation part being present in the housing. The non-interlinking extends over a non-interlinked area inside the airfoil portion of the fiber reinforcement included between the root portion and the vane tip portion in the longitudinal direction and between the leading edge portion and the trailing edge portion in the transverse direction, the non-interlinking also opening outside the airfoil portion of the fiber reinforcement.

A method of manufacturing a component for a gas turbine engine includes applying a thermoplastic polymer sheet over a composite body for the component; applying a shield over part of the composite body, the shield terminating at an end which overlies the thermoplastic polymer sheet and defines an interface between shielded and unshielded regions of the component; and pressing the shield into the thermoplastic polymer sheet so that the thermoplastic polymer sheet deforms around the end of the shield, such that the exterior profile of the component at the interface between the shielded and unshielded regions is flush.

A beam steering system in which the printhead follows a printpath along a curve, such as printing of a heat exchanger thin walls, typically undergoes errors due to varying beam angles, beam focus and beam speed. The present disclosure provides solutions to error reduction and increases reliability for printing rings and hollow objects related to 3D printing. Accordingly, a wall described by a curve function, may be fabricated using a printhead, which is moved in a print path that keeps the print lines orthogonal to the print path and tangent to the inner center line curve between the outer wall and the inner wall.

A method of manufacturing a fabric structure for use in manufacturing a composite aircraft blade. The method comprises: combining yarns including both reinforcing material filaments and a matrix material with yarns of reinforcing material filaments and/or yarns including at least one filament of matrix material; or by combining yarns of reinforcing material filaments with yarns including at least one filament of matrix material; or by combining yarns each comprising both reinforcing material filaments and matrix material. Combining may comprise weaving, knitting or braiding. The matrix material may be a thermoplastic.

Methods for manufacturing composite components having complex geometries are provided. In one exemplary aspect, a method includes laying up each of a plurality of laminates to an initial shape with a substantially planar geometry or a gently curved geometry. Then, a laid up laminate is formed to a final shape for each predefined section defined by the composite component to be manufactured. Thereafter, the laminates formed to their respective final shapes are stacked to build up the complex geometry of the composite component. Next, the composite component can be cured and finish machined as necessary to form the completed composite component.

A composite blade is formed by laying up composite layers in which reinforced fibers are impregnated with resin. The composite layers are laid up in a blade thickness direction that is a direction connecting a suction side and a pressure side of the composite blade. The composite blade includes a thick part that has a surface layer area from a surface of the thick part to a predetermined depth in the blade thickness direction and a deep layer area at a depth larger than the predetermined depth from the surface in the blade thickness direction. A median value in a predetermined range of thicknesses of each composite layer in the surface layer area is smaller than a median value in a predetermined range of thicknesses of each composite layer in the deep layer area.

A fiber-reinforced component for use in a gas turbine engine includes a fiber sleeve forming a cooling channel and a plurality of fiber plies enclosing the fiber sleeve, with the plurality of fiber plies forming first and second walls separated by the fiber sleeve. The fiber-reinforced component further includes a matrix material between fibers of the fiber sleeve and the plurality of fiber plies.

There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange.

An airfoil for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil section extending between a leading edge and a trailing edge in a chordwise direction and extending between a tip and a root section in a spanwise direction. A composite core defines the root section and a portion of the airfoil section. First and second skins extend along opposed sides of the composite core. 12. A method of forming a composite airfoil is also disclosed.