Systems, devices, and methods including a leading edge tubular member; an upper tubular member; a lower tubular member; one or more upper rib members connected between the leading edge tubular member and the upper tubular member; one or more lower rib members connected between the leading edge tubular member and the lower tubular member; a rigid sandwich shell disposed between the upper tubular member and the leading edge tubular member; and a sandwich shear web disposed between the upper tubular member and the lower tubular member; where the rigid sandwich shell and the sandwich shear web form a D-shape.

Structural composite airfoils include a primary structural element and a secondary structural element defining the trailing 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 upper skin panel extends from an upper leading edge end to an upper trailing edge end, and the lower skin panel extends from a lower leading edge end to a lower trailing edge end. The lower leading edge end of the lower skin panel is coupled to the upper leading edge end of the upper skin panel within the leading edge region of the primary structural element.

Structural composite airfoils include a primary structural element and a secondary structural element defining the trailing 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 upper skin panel extends from an upper leading edge end to an upper trailing edge end, and the lower skin panel extends from a lower leading edge end to a lower trailing edge end. The lower leading edge end of the lower skin panel is coupled to the upper leading edge end of the upper skin panel within the leading edge region of the primary structural element.

A device and a process for manufacturing a composite part, the device comprising four molding mandrels that can be arranged in a mold arrangement in which they form a mold for the composite part, as well as a locking mandrel configured to lock the molding mandrels in the mold arrangement and to be extracted from between the molding mandrels to release the molding mandrels from their mold arrangement. The locking mandrel extends from one longitudinal end of the molding mandrels to another opposite longitudinal end of the molding mandrels.

An exterior panel is configured to accommodate high thermal stresses imposed on exterior surfaces of aerospace transport vehicles during hypersonic flight. The exterior panel is formed of a superplastic material such as a titanium alloy, and includes an exterior skin and a plurality of cooling tubes that extend through the panel. The exterior panel further includes an interior skin configured to be attached to a frame member such as a rib, stringer, or spar of the transport vehicle. The tubes pass through a multicellular core, which is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior skin, the tubes, and the interior skin. A cooling fluid, which may be a gas or liquid, including a fuel, may be pumped through the tubes to cool the exterior panel.

An exterior panel is configured to accommodate high thermal stresses imposed on exterior surfaces of aerospace transport vehicles during hypersonic flight. The exterior panel is formed of a superplastic material such as a titanium alloy, and includes an exterior skin and a plurality of cooling tubes that extend through the panel. The exterior panel further includes an interior skin configured to be attached to a frame member such as a rib, stringer, or spar of the transport vehicle. The tubes pass through a multicellular core, which is sandwiched between the exterior and interior skins to impart tensile and compressive strength to the exterior panel. In one disclosed method, the core is superplastic formed and diffusion bonded to the exterior skin, the tubes, and the interior skin. A cooling fluid, which may be a gas or liquid, including a fuel, may be pumped through the tubes to cool the exterior panel.

A tool for fabricating a control surface is disclosed. In various embodiments, the tool includes a first block defining a longitudinal direction running between a leading edge end and a trailing edge end; a first sidewall spaced a first lateral distance from the first block to form a first closeout channel running in the longitudinal direction between the first block and the first sidewall; and a second sidewall configured to form a second closeout channel running in the longitudinal direction, the second closeout channel disposed laterally opposite the tool from the first closeout channel.

A vertical take-off and landing (VTOL) aircraft has a first drivable configuration in which the pilot seat is positioned between the wings and facing the direction of forward travel. The VTOL may be driven in the first configuration as a normal automobile. In the first configuration the wings are aligned with the direction of forward travel and their surfaces are vertically oriented. In the first configuration, the VTOL may also attain altitude and be maneuvered using thrust from propulsion sources. In a second configuration, the pilot seat is rotated 90 degrees from the direction of forward travel to a direction of forward flight. Forward flight is achieved using thrust to rotate the wings from the vertical orientation to a lift-providing orientation. In concert with the rotation of the wings, the pi lot seat is counter-rotated to maintain the seat facing the direction of forward flight.

An airfoil system is provided that includes an airfoil and an electric device. The airfoil includes a first exterior surface, a second exterior surface, a first airfoil segment and a second airfoil segment attached to the first airfoil segment. The airfoil extends widthwise between the first exterior surface and the second exterior surface. The first airfoil segment forms the first exterior surface. The second airfoil segment forms the second exterior surface. The electric device is embedded within the airfoil between the first airfoil segment and the second airfoil segment.

An airfoil system is provided that includes an airfoil and an electric device. The airfoil includes a first exterior surface, a second exterior surface, a first airfoil segment and a second airfoil segment attached to the first airfoil segment. The airfoil extends widthwise between the first exterior surface and the second exterior surface. The first airfoil segment forms the first exterior surface. The second airfoil segment forms the second exterior surface. The electric device is embedded within the airfoil between the first airfoil segment and the second airfoil segment.