Methods, systems, and apparatuses are disclosed for the manufacture of composite components having incorporated reinforcing structures machined into composite material substrates, and composite components manufactured according to disclosed methods, and assemblies and larger structures comprising the composite material components.

Systems and methods for a caul plate for an irregular surface. One embodiment is a caul plate for co-curing or co-bonding a first composite part and a second composite part. A body of the caul plate includes a lower surface to face a top surface of the first composite part, a reference edge to locate the second composite part on the first composite part, and an upper surface that is opposite to the lower surface. The lower surface includes one or more bends to match one or more slopes in the top surface of the first composite part. The one or more bends correspond with ply changes in the first composite part.

Structural composite airfoils include a primary structural element, a secondary structural element defining the trailing edge of the structural composite airfoil, and a discrete leading edge structure defining the leading edge of the structural composite airfoil. The primary structural element includes an upper skin panel, a lower skin panel, and a middle C-channel spar that is coupled to the upper skin panel and the lower skin panel. The discrete leading edge structure is coupled to the upper leading edge end of the upper skin panel and to the lower leading edge end of the lower skin panel. The upper skin panel may include a first panel bend adjacent the discrete leading edge structure, and the lower skin panel may include a second panel bend adjacent the discrete leading edge structure.

Structural composite airfoils include a primary structural element, a secondary structural element defining the trailing edge of the structural composite airfoil, and a discrete leading edge structure defining the leading edge of the structural composite airfoil. The primary structural element includes an upper skin panel, a lower skin panel, and a middle C-channel spar that is coupled to the upper skin panel and the lower skin panel. The discrete leading edge structure is coupled to the upper leading edge end of the upper skin panel and to the lower leading edge end of the lower skin panel. The upper skin panel may include a first panel bend adjacent the discrete leading edge structure, and the lower skin panel may include a second panel bend adjacent the discrete leading edge structure.

A composite structural member including at least one first flange element made from a first composite material, and at least one first web element made from a second composite material. The at least one first web element is connected to at least one first flange element in a non-coplanar manner along a corresponding mutual first edge via a first corner element made from a third composite material, the mutual first edge extending along a first direction. The third composite material includes a corresponding first plurality of third composite material first fibers and a corresponding second plurality of third composite material second fibers embedded in a corresponding third composite material matrix in a non-parallel orientation with respect to the third composite material first fibers, wherein the third composite material first fibers are nominally orthogonal to the mutual first edge or to the first direction.

A composite structural member including at least one first flange element made from a first composite material, and at least one first web element made from a second composite material. The at least one first web element is connected to at least one first flange element in a non-coplanar manner along a corresponding mutual first edge via a first corner element made from a third composite material, the mutual first edge extending along a first direction. The third composite material includes a corresponding first plurality of third composite material first fibers and a corresponding second plurality of third composite material second fibers embedded in a corresponding third composite material matrix in a non-parallel orientation with respect to the third composite material first fibers, wherein the third composite material first fibers are nominally orthogonal to the mutual first edge or to the first direction.

A skin panel configured for attachment to an aircraft structure is constructed of a composite material and has a continuous, smooth outer surface; a continuous, smooth inner surface that is configured for attachment to an aircraft structure; a peripheral edge that extends entirely around the skin panel and has a continuous, smooth surface and a plurality of cavities inside the material of the skin panel. The cavities reduce the weight of the skin panel without significantly detracting from the compression strength and tensile strength of the skin panel.

A skin panel configured for attachment to an aircraft structure is constructed of a composite material and has a continuous, smooth outer surface; a continuous, smooth inner surface that is configured for attachment to an aircraft structure; a peripheral edge that extends entirely around the skin panel and has a continuous, smooth surface and a plurality of cavities inside the material of the skin panel. The cavities reduce the weight of the skin panel without significantly detracting from the compression strength and tensile strength of the skin panel.

A composite airfoil is disclosed. In various embodiments, a composite airfoil as disclosed herein includes an outer skin comprising one or more layers of carbon fiber composite material, the outer skin defining an aerodynamic surface having a leading edge; and a reinforcement material comprising a roll of fiberglass reinforced fabric positioned behind the outer skin along at least a portion of the leading edge.

A composite airfoil is disclosed. In various embodiments, a composite airfoil as disclosed herein includes an outer skin comprising one or more layers of carbon fiber composite material, the outer skin defining an aerodynamic surface having a leading edge; and a reinforcement material comprising a roll of fiberglass reinforced fabric positioned behind the outer skin along at least a portion of the leading edge.