A composite core assembly includes a composite core structure having internal material interfaces and an attachment rail coupled to the composite core structure. The attachment rail includes a first planar surface and a second planar surface adjoined with the first planar surface. The first planar surface is arranged parallel to an internal material interface plane of the composite core structure, and the first planar portion is at least partially integrated into the composite core structure in an internal material interface plane. At least a portion of the first planar surface extends beyond a perimeter surface of the composite core structure, and the second planar surface is configured to attach to the surrounding support member. The core material does not have net edge facets or flat edges positioned next to surrounding structure, and/or may not have a structure arranged parallel to the adjacent support structure to attach to the support structure.

A method of curing an aircraft component including applying a temperature sensitive adhesive to a surface of a component, the surface having a contour; positioning a heating tool including a manifold with a ventilation path such that the ventilation path is adjacent to the surface by aligning the ventilation path to the contour of the component; and heating the surface of the component with uniform airflow from the ventilation path; wherein the manifold includes a chamber with a diverging portion configured to provide uniform airflow through the ventilation path to provide heating to the surface.

A flow body for an aircraft includes a skin having a first flow surface, having a flow influencing section with at least one first layer, at least one separator layer, at least one third layer, and at least one base layer. The first layer includes lithiated carbon fibers embedded into a matrix to form a negative electrode. The third layer includes carbon fibers with an electrode active material coating to form a positive electrode. The separator layer includes a non-conductive material for electrically isolating the first layer and the third layer from each other. The flow influencing section is configured for selectively raising a region of the arrangement of first layer, separator layer and third layer from the base layer upon application of a voltage between the first and third layers to form a bump on the flow body.

A flow body for an aircraft includes a skin having a first flow surface, having a flow influencing section with at least one first layer, at least one separator layer, at least one third layer, and at least one base layer. The first layer includes lithiated carbon fibers embedded into a matrix to form a negative electrode. The third layer includes carbon fibers with an electrode active material coating to form a positive electrode. The separator layer includes a non-conductive material for electrically isolating the first layer and the third layer from each other. The flow influencing section is configured for selectively raising a region of the arrangement of first layer, separator layer and third layer from the base layer upon application of a voltage between the first and third layers to form a bump on the flow body.

A method for forming a fiber-reinforced thermoplastic control surface may comprise: stacking plies of thermoplastic composite sheets to a first desired thickness to form a first skin; stacking plies of thermoplastic composite sheets to a second desired thickness to form a second skin; forming the first skin in a first contour; forming the second skin in a second contour; forming a stiffening member including a thermoplastic resin, the stiffening member including a shape having a plurality of peaks and troughs; assembling the stiffening member between the first skin and the second skin; and joining the stiffening member to the first skin and the second skin.

An aircraft structure including a first surface and a second surface. The first surface and the second surface are bonded together via a plurality of discrete adhesive sections arranged in a herringbone pattern or a support between the first surface and the second surface, wherein the support includes spaced apart ribs with discrete adhesive sections located between the spaced apart ribs.

An aircraft structure including a first surface and a second surface. The first surface and the second surface are bonded together via a plurality of discrete adhesive sections arranged in a herringbone pattern or a support between the first surface and the second surface, wherein the support includes spaced apart ribs with discrete adhesive sections located between the spaced apart ribs.

An example aircraft wing includes a skin, a composite shear tie, a stringer base charge overlaying the skin, and a stringer overlaying the stringer base charge. The composite shear tie includes a shear-tie web, a first shear-tie flange extending from a first side of the shear-tie web, a second shear-tie flange extending from a second side of the shear-tie web, and a first shear-tie tab extending from an end of the first side of the shear-tie web. The stringer includes a stringer web, a first stringer flange extending from a first side of the stringer web, and a second stringer flange extending from a second side of the stringer web. The first stringer flange is stitched to and integrated with the stringer base charge and the skin. Further, the first shear-tie flange is stitched to and integrated with the first stringer flange.

A blade made of layered material, such as composite material, configured for exposure to a fluid flow, comprises skins (1, 2) defined between a leading edge (3) and a trailing edge (4) which skins in cross-section form a flow profile. The layered material may consist of several layers of fiber material (5, 5′, . . . ) impregnated with a matrix material, wherein layers of fiber material each comprise a respective body portion (6, 6′, . . . , 13) between and transverse to the skins and each at least a respective skin portion (7, 7′, . . . ; 8, 8′, . . . ) that forms part of the skins. The said skin portions all extend from the related body portion in the direction of the trailing edge. Of said skin portions at least two consecutive skin portions of the one skin overlap and/or two consecutive skin portions of the other skin overlap each other.

A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.