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.

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.

A method of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member formed of dry fiber material comprised of reinforcing fibers. The radius filler element is formed of a radius filler material. The method also includes infusing resin into the dry fiber material, and chemically reacting the resin with the radius filler material to create a mixture of resin and radius filler material along side surface interfaces between the radius filler element and the composite base member. The method additionally includes curing or solidifying the resin, and allowing solvent in the resin to evaporate causing hardening of the mixture and bonding of the radius filler element to the composite base member, and resulting in a cured composite 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.

Aspects of the disclosure are directed to a toolset configured to fabricate a component of an aircraft, the toolset comprising: a mold base configured to seat at least one mandrel, a mold lid configured to be coupled to the mold base, and at least one driver block that is integral with the mold lid and projects from an interior surface of the mold lid.

In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

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.

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.