An additive manufactured airframe structure includes a first additive manufactured fuselage segment including a first outer wall that extends in a normal direction from a first end to a second end, and also includes a plurality of reinforcement elements extending from the second end of, and away from, the first outer wall in the normal direction. The airframe structure also includes a second additive manufactured fuselage segment formed separately from the first additive manufactured fuselage segment and including a second outer wall that extends in the normal direction from a first end to a second end, and a plurality of receiving channels extending along the second outer wall. The plurality of reinforcement elements are received in the plurality of receiving channels and link together the first and second additive manufactured fuselage segments.

An additive manufactured airframe structure includes a first additive manufactured fuselage segment including a first outer wall that extends in a normal direction from a first end to a second end, and also includes a plurality of reinforcement elements extending from the second end of, and away from, the first outer wall in the normal direction. The airframe structure also includes a second additive manufactured fuselage segment formed separately from the first additive manufactured fuselage segment and including a second outer wall that extends in the normal direction from a first end to a second end, and a plurality of receiving channels extending along the second outer wall. The plurality of reinforcement elements are received in the plurality of receiving channels and link together the first and second additive manufactured fuselage segments.

In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the mold, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the mold. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the mold, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies.

An example method of manufacturing a wing includes providing a wing frame. The wing frame includes a primary spar, a drag spar, a plurality of transverse frame elements having at least one spar joiner, and a plurality of mounting elements. The primary spar is coupled to the drag spar via the at least one spar joiner. The method further includes placing the wing frame into a mold, wherein the mold defines a shape of the wing. The method also includes injecting the mold with an air-filled matrix material, such that the air-filled matrix material substantially encases the wing frame and fills the defined shape of the wing, and such that the plurality of transverse frame elements provide torsional rigidity to the wing.

An example method of manufacturing a wing includes providing a wing frame. The wing frame includes a primary spar, a drag spar, a plurality of transverse frame elements having at least one spar joiner, and a plurality of mounting elements. The primary spar is coupled to the drag spar via the at least one spar joiner. The method further includes placing the wing frame into a mold, wherein the mold defines a shape of the wing. The method also includes injecting the mold with an air-filled matrix material, such that the air-filled matrix material substantially encases the wing frame and fills the defined shape of the wing, and such that the plurality of transverse frame elements provide torsional rigidity to the wing.

The invention relates to a method for manufacturing a box-shaped monolithic structure with a cavity by curing a fiber-reinforced prepreg material. The method comprises using two or more elongated and internally hollow support tools which have a complementary form to that of the cavities to be manufactured, and a composition based on reinforcement material and polymer suitable to allow the passage from a rigid state to a flexible elastomeric state and vice versa in response to heating/cooling down. In the rigid state, the support tools allow the direct lamination of the prepreg material on their external walls and are configured to set the flexible elastomeric state at a temperature lower than the curing temperature and higher than 50? C. During the curing operation, the curing pressure is applied both outside the structure being formed and inside the support tools, whose walls have become flexible, to push on the prepreg material to be cured.

The invention relates to a method for manufacturing a box-shaped monolithic structure with a cavity by curing a fiber-reinforced prepreg material. The method comprises using two or more elongated and internally hollow support tools which have a complementary form to that of the cavities to be manufactured, and a composition based on reinforcement material and polymer suitable to allow the passage from a rigid state to a flexible elastomeric state and vice versa in response to heating/cooling down. In the rigid state, the support tools allow the direct lamination of the prepreg material on their external walls and are configured to set the flexible elastomeric state at a temperature lower than the curing temperature and higher than 50? C. During the curing operation, the curing pressure is applied both outside the structure being formed and inside the support tools, whose walls have become flexible, to push on the prepreg material to be cured.

In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a cavity with a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the cavity. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity.

A leading edge structure for providing an aerodynamic surface of an aircraft is disclosed having a skin structure, the skin structure providing an outer aerodynamic surface and an inner surface, both surfaces extending in a chordwise and spanwise direction of the structure, and a plurality of structural members, each structural member being connected to the inner surface of the skin structure and extending in the chordwise direction along the inner surface, wherein the structural members are integrally formed with the inner surface of the skin structure. The disclosure is also related to an aircraft wing, aircraft tailplane, wing box structure, wing or wing structure and an aircraft including the leading edge structure.

A leading edge structure for providing an aerodynamic surface of an aircraft is disclosed having a skin structure, the skin structure providing an outer aerodynamic surface and an inner surface, both surfaces extending in a chordwise and spanwise direction of the structure, and a plurality of structural members, each structural member being connected to the inner surface of the skin structure and extending in the chordwise direction along the inner surface, wherein the structural members are integrally formed with the inner surface of the skin structure. The disclosure is also related to an aircraft wing, aircraft tailplane, wing box structure, wing or wing structure and an aircraft including the leading edge structure.