A method of manufacturing a tiltrotor wing structure including providing a spar mold having a plurality of bores extending from an exterior surface of the mold to an interior surface of the mold, the plurality of bores corresponding to a plurality of primary coordination holes in a spar member, the spar mold having a periphery defined by a top edge, a bottom edge and outboard ends; selecting a plurality of resin impregnated plies to ensure that the plies continuously extend beyond the periphery of the spar mold; laying the plies in the spar mold; curing the plies in the mold to form a cured spar member that extends beyond the periphery of the spar mold; and accurately drilling a plurality of primary coordination holes in the cured spar member in the spar mold using a tool positioned in the plurality of bores.

A method of manufacturing a tiltrotor wing structure including providing a spar mold having a plurality of bores extending from an exterior surface of the mold to an interior surface of the mold, the plurality of bores corresponding to a plurality of primary coordination holes in a spar member, the spar mold having a periphery defined by a top edge, a bottom edge and outboard ends; selecting a plurality of resin impregnated plies to ensure that the plies continuously extend beyond the periphery of the spar mold; laying the plies in the spar mold; curing the plies in the mold to form a cured spar member that extends beyond the periphery of the spar mold; and accurately drilling a plurality of primary coordination holes in the cured spar member in the spar mold using a tool positioned in the plurality of bores.

A method of manufacturing stiffened structural panel for an aircraft including a main sheet made of composite material with unidirectional fibers, and a stiffening structure secured to the main sheet and made of a composite material comprising a resin and chopped fibers, the stiffening structure including on the one hand a base adhering to one of the two lateral faces of the main sheet, and a network of stiffeners in the form of a grid projecting from the base. The method includes a step of compression molding the stiffening structure from a block formed of a prepolymer reinforced with chopped fibers.

A method for manufacturing a one-piece reinforced structure and obtained structure is provided, the method using base components made of partially-cured composite material and joining the base components together, applying a coating made of composite material on the base components, and applying heat on the assembly formed by the base components covered with the coating until a complete curing of the assembly is obtained, such that a one-piece reinforced structure made of composite material is obtained formed by the coating and the base components adhered to the coating, wherein the base components that form part of the very manufactured structure act as a mould during the manufacturing process, thus preventing the need to use moulds on which the composite material is deposited that must be subsequently removed from the final obtained structure.

A method for manufacturing the trailing edge ribs and the bearing ribs of trailing edges of aircraft lifting surfaces, in which the trailing edge ribs and the bearing ribs are made by joining simple C-shaped parts and/or simple L-shaped parts so as to obtain the final trailing edge ribs and bearing ribs. The manufacturing of the simple C-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs, and the manufacturing of the simple L-shaped parts uses the same tooling both for the trailing edge ribs and the bearing ribs.

Methods of manufacturing of aerospace structures are disclosed. More specifically, methods of manufacturing relatively lightweight yet strong aerospace structures. In one embodiment, the method includes the addition of a volume of a rigid and flexible polyurethane mixture into a mold to create a composite structure. In one aspect, the method includes the integration of special structures within a larger structure to remove traditionally structurally weak or vulnerable areas.

The trailing edge structure of an aircraft wing is subjected, in use, to high temperature efflux from an aircraft's engines. Such elevated temperatures can detrimentally affect the ultimate tensile strength of the trailing edge. An aircraft wing component includes composite material having a first portion including a metal matrix containing reinforcing material, and a second portion including a metal matrix containing hollow metal ceramic spheres, the second portion being adjacent a surface of the composite material. The provision of two portions, one of which contains reinforcing material and the other comprising hollow spheres means that the composite material has both structural strength and heat shielding qualities where they are needed most in the component. The portion of composite containing the hollow metal ceramic spheres acts as an embedded layer of heat insulation.

The trailing edge structure of an aircraft wing is subjected, in use, to high temperature efflux from an aircraft's engines. Such elevated temperatures can detrimentally affect the ultimate tensile strength of the trailing edge. An aircraft wing component includes composite material having a first portion including a metal matrix containing reinforcing material, and a second portion including a metal matrix containing hollow metal ceramic spheres, the second portion being adjacent a surface of the composite material. The provision of two portions, one of which contains reinforcing material and the other comprising hollow spheres means that the composite material has both structural strength and heat shielding qualities where they are needed most in the component. The portion of composite containing the hollow metal ceramic spheres acts as an embedded layer of heat insulation.

A manufacturing method is provided. A first end of a set of spars is coupled to a first skin of a flight control surface. A set of ribs is interlocked with the set of spars and a first end of the set of ribs is coupled to the first skin. A second skin is coupled to a second end of the set of spars and a second end of the set of ribs.

A manufacturing method is provided. A first end of a set of spars is coupled to a first skin of a flight control surface. A set of ribs is interlocked with the set of spars and a first end of the set of ribs is coupled to the first skin. A second skin is coupled to a second end of the set of spars and a second end of the set of ribs.