A rib can be manufactured comprising two opposing outer skins and a plurality of internal reinforcement members connecting the skins together.

A cover panel for an aircraft including: a first region, a second region for forming an overlap with a second panel, and a ramp, wherein at least a portion of the ramp is between the first and second regions, wherein the ramp includes a tapered region such that a width of the ramp tapers towards a free-edge of the first region, and wherein the free-edge is configured to form a butt-joint with the second panel.

A cover panel for an aircraft including: a first region, a second region for forming an overlap with a second panel, and a ramp, wherein at least a portion of the ramp is between the first and second regions, wherein the ramp includes a tapered region such that a width of the ramp tapers towards a free-edge of the first region, and wherein the free-edge is configured to form a butt-joint with the second panel.

A method of forming a structural honeycomb includes cutting and folding a substrate sheet according to predetermined cutting and folding patterns and fold angles that cause the sheet to form a honeycomb having cells that each have at least one face abutting, or nearly abutting, the face of another cell. The honeycomb is then stabilized by joining abutting, or nearly abutting, faces to hold the honeycomb together. The honeycomb may have a prespecified three-dimensional shape. The folding pattern may include corrugation, canted corrugation, or zig-zag folds. Joining may employ fixed and/or reversible joinery, including slotted cross section, tabbed strip, angled strip, integral skin, sewn, or laced. At least some folds may be partially-closed to create bends and twists in the honeycomb structure. Some surfaces of the honeycomb may be covered with a skin or face sheet. The substrate sheet may have flexible electronic traces.

A method of forming a structural honeycomb includes cutting and folding a substrate sheet according to predetermined cutting and folding patterns and fold angles that cause the sheet to form a honeycomb having cells that each have at least one face abutting, or nearly abutting, the face of another cell. The honeycomb is then stabilized by joining abutting, or nearly abutting, faces to hold the honeycomb together. The honeycomb may have a prespecified three-dimensional shape. The folding pattern may include corrugation, canted corrugation, or zig-zag folds. Joining may employ fixed and/or reversible joinery, including slotted cross section, tabbed strip, angled strip, integral skin, sewn, or laced. At least some folds may be partially-closed to create bends and twists in the honeycomb structure. Some surfaces of the honeycomb may be covered with a skin or face sheet. The substrate sheet may have flexible electronic traces.

A composite wingbox structure formed of reinforced thermoplastic. The composite includes carbon fiber reinforcement and a plurality of insulation elements to localize the heat formed during the process of manufacturing the structure. The process of manufacturing the wingbox includes the steps of interleaving a series of insulations elements within a plurality of laminae and consolidating the insulation elements and laminae to form a laminate. The laminate is then aligned with a support structure such that the insulation elements overlie the supports structure. The laminate is then fused to the support structure using a non-contact heating process, such as inductive welding.

A composite wingbox structure formed of reinforced thermoplastic. The composite includes carbon fiber reinforcement and a plurality of insulation elements to localize the heat formed during the process of manufacturing the structure. The process of manufacturing the wingbox includes the steps of interleaving a series of insulations elements within a plurality of laminae and consolidating the insulation elements and laminae to form a laminate. The laminate is then aligned with a support structure such that the insulation elements overlie the supports structure. The laminate is then fused to the support structure using a non-contact heating process, such as inductive welding.

There is provided a composite structure for an aerodynamic component having an aerofoil-like cross-section and a leading edge, the composite structure being in the form of a torsion box arrangement made from composite materials and having a core, the torsion box having a forward wall, an aft wall, a top wall and a bottom wall, together defining the core, the front wall being formed as the leading edge of the aerodynamic component. Also provided is a load-bearing composite structure for use with an aerodynamic component and configured for supporting at least one external load, this composite structure being made from composite materials and configured for being joined to the external aerodynamic surface of the aerodynamic component such as to be in overlying abutting relationship with at least a contact surface portion of the external aerodynamic surface, including the leading edge, at least a forward portion of each of the suction surface and the pressure surface thereof.

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.