An electrically decoupled jet engine. The electrically decoupled jet engine includes a combustion chamber which creates a toroidal flow of air and a rotational electric motor which drives a fuel supply into the combustion chamber. The toroidal flow of air is mixed with the fuel and combusted in the combustion chamber to create thrust.

A bonded structure is described. The bonded structure includes an outer structure including a close tolerance hole associated with a first accuracy level. The bonded structure includes an interior structure comprising an oversized hole associated with a second accuracy level that is different from the first accuracy level. The bonded structure includes an elastomeric grommet disposed in the oversized hole. The bonded structure includes one or more spacers between the outer structure and the interior structure providing a space between the outer structure and the interior structure. The bonded structure includes a fastener positioned in the close tolerance hole and in the oversized hole. The bonded structure includes a bonding media disposed in the space between the outer structure and the interior structure via one or more channels of the fastener. The bonding media, elastomeric grommet, and oversized hole collectively position the interior structure relative to the outer structure.

A bonded structure is described. The bonded structure includes an outer structure including a close tolerance hole associated with a first accuracy level. The bonded structure includes an interior structure comprising an oversized hole associated with a second accuracy level that is different from the first accuracy level. The bonded structure includes an elastomeric grommet disposed in the oversized hole. The bonded structure includes one or more spacers between the outer structure and the interior structure providing a space between the outer structure and the interior structure. The bonded structure includes a fastener positioned in the close tolerance hole and in the oversized hole. The bonded structure includes a bonding media disposed in the space between the outer structure and the interior structure via one or more channels of the fastener. The bonding media, elastomeric grommet, and oversized hole collectively position the interior structure relative to the outer structure.

Expandable components for aerial vehicles may include an outer structure formed of carbon fiber, an adhesive bladder disposed within the outer structure, and expanding foam materials inserted into the adhesive bladder. The expandable components may be configured to transform from a compressed configuration to an expanded configuration upon application of heat and/or pressure. For example, in the compressed configuration, the outer structure, adhesive bladder, and expanding foam materials may be folded, rolled, or compressed for storage or transport. In the expanded configuration, the expanding foam materials may expand and cure within the adhesive bladder, the adhesive bladder may expand, bond, and cure inside the outer structure, and the outer structure may expand and cure to a desired shape or size.

A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.

A structure includes a skin and a foam member. The foam member has a molded contour, the mold contour being configured to provide tooled surface for the skin. When the skin is a composite skin, the foam member provides support for the skin so that the skin can be cured under heat and pressure. A method of making the foam member for a foam stiffened structure includes creating a mold having an interior cavity which resembles a desired shape the foam member. A subsequent step involves introducing a foam mixture into the mold. Next, the foam mixture is allowed to polymerize so as to expand and distribute within the cavity of the mold. The method further includes selectively controlling a density of the foam member in the mold. The foam member is at least partially cured. The foam member is assembled with a skin to produce the foam stiffened structure.

Additive manufactured airframe structure having a plurality of additive manufactured airframe segments operable to be linked together in an assembled direction. Each of the plurality of additive manufactured airframe segments are separate from one another in an unassembled configuration. Plurality of reinforcement elements operable to be received in a receiving portion of the plurality of airframe segments and extending through the plurality of airframe segments in a normal direction. Receiving portion is located on the interior of a respective one of the plurality of airframe segments.

Additive manufactured airframe structure having a plurality of additive manufactured airframe segments operable to be linked together in an assembled direction. Each of the plurality of additive manufactured airframe segments are separate from one another in an unassembled configuration. Plurality of reinforcement elements operable to be received in a receiving portion of the plurality of airframe segments and extending through the plurality of airframe segments in a normal direction. Receiving portion is located on the interior of a respective one of the plurality of airframe segments.

Provided is a method for forming a co-cured composite article. The method includes: providing a bag carrier; providing a vacuum bag, wherein the vacuum bag at least partially surrounds the bag carrier; providing an outer skin, wherein the outer skin at least partially surrounds the vacuum bag; forming a space between the bag carrier and the outer skin; and providing a filler between the outer skin and the bag carrier.

Provided is a method for forming a co-cured composite article. The method includes: providing a bag carrier; providing a vacuum bag, wherein the vacuum bag at least partially surrounds the bag carrier; providing an outer skin, wherein the outer skin at least partially surrounds the vacuum bag; forming a space between the bag carrier and the outer skin; and providing a filler between the outer skin and the bag carrier.