An aircraft component including a structural foam having a predetermined shape, an outer flange located near a first end of the structural foam, an inner flange located near a second end of the structural foam, a web skin encapsulating the inner flange and at least a portion of the structural foam wherein the structural foam is affixed to the web skin, wherein the aircraft component comprises a portion of a blended wing body aircraft (BWB), the BWB having no demarcation between a wing and a main body of the BWB.

A system for manufacturing modular aircraft includes at least at least a common tooling component, including at least one or more of a first component in a shape of a nose and a second component in a shape of a wing. The system further including at least a modular tooling component in a shape of a main body, wherein connecting the at least a common tooling components to the at least modular component forms a mold in a shape of at least a portion of a blended wing body (BWB) aircraft with no clear demarcation between the shape of the wing and a shape of a main body along an edge of the shape of the BWB.

Method for manufacturing a base structure (8) of an aeronautical torsion box (1) for an aircraft (11) characterized in that it comprises the steps of: a.providing at least a fresh skin (3), at least one fresh stringer (4), at least a fresh front spar (5) and fresh rear spar (6), b.positioning the fresh skin (3), the at least one fresh stringer, the fresh spars (5, 6) in a curing tool in a configuration corresponding to that of a base structure (8), c.subjecting the structure (8) to a single curing cycle, obtaining a cured base structure (8).

Method for manufacturing a base structure (8) of an aeronautical torsion box (1) for an aircraft (11) characterized in that it comprises the steps of: a.providing at least a fresh skin (3), at least one fresh stringer (4), at least a fresh front spar (5) and fresh rear spar (6), b.positioning the fresh skin (3), the at least one fresh stringer, the fresh spars (5, 6) in a curing tool in a configuration corresponding to that of a base structure (8), c.subjecting the structure (8) to a single curing cycle, obtaining a cured base structure (8).

A solar powered aircraft having segmented wings that can be reconfigured during flight to optimize collection of solar energy are described. The aircraft have rigid construction that is resistant to inclement weather and is configured to rely on free flight control at high altitude and under conventional conditions, thereby providing flight duration in excess of 2 months. The aircraft is particularly suitable for use as part of a telecommunications network. A telecommunications network incorporating such aircraft is also discussed.

A solar powered aircraft having segmented wings that can be reconfigured during flight to optimize collection of solar energy are described. The aircraft have rigid construction that is resistant to inclement weather and is configured to rely on free flight control at high altitude and under conventional conditions, thereby providing flight duration in excess of 2 months. The aircraft is particularly suitable for use as part of a telecommunications network. A telecommunications network incorporating such aircraft is also discussed.

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.

A method is provided during which a thermoplastic rib is arranged with a thermoplastic spar. A first flange of the thermoplastic rib is abutted against the thermoplastic spar. The first flange of the thermoplastic rib is ultrasonic welded to the thermoplastic spar using a tilted ultrasonic horn. A centerline of the tilted ultrasonic horn is angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.

An aerodynamic profile for an aircraft, comprises a core (6, 7, 8) made of foam, a skin (11, 12) defining an outer surface of the wing and cloths (14) form-ing spars and/or ribs. The profile comprises a wing, a canard, a horizontal stabiliser, a vertical stabiliser, an aileron, a flaperon, a wingtip winglet, an elevator, an elevon, a rudder or a flap.