Woven preforms, for example those used for jet aircraft engine fancases, may need additional stiffeners to improve the strength and/or dynamic performance of the preform assembly, as well as to serve as attachment points. The present invention describes several improved woven preforms that include circumferential or axial stiffeners, as well as methods of manufacturing the same. One embodiment includes circumferential stiffeners added to a woven preform. Another embodiment includes sub-preforms with integral flanges that combine to make integral stiffeners. A further embodiment includes an intermediate stiffener wrapped onto a base sub-preform wrap, wherein the intermediate stiffener wrap incorporates intermediate stiffeners. Another embodiment incorporates bifurcations in one or more layers of an outermost wrap of a multi-layer fabric composite that forms a preform, wherein the bifurcated outer wrap is folded to form stiffeners that may be oriented circumferentially or axially.

Woven preforms, for example those used for jet aircraft engine fancases, may need additional stiffeners to improve the strength and/or dynamic performance of the preform assembly, as well as to serve as attachment points. The present invention describes several improved woven preforms that include circumferential or axial stiffeners, as well as methods of manufacturing the same. One embodiment includes circumferential stiffeners added to a woven preform. Another embodiment includes sub-preforms with integral flanges that combine to make integral stiffeners. A further embodiment includes an intermediate stiffener wrapped onto a base sub-preform wrap, wherein the intermediate stiffener wrap incorporates intermediate stiffeners. Another embodiment incorporates bifurcations in one or more layers of an outermost wrap of a multi-layer fabric composite that forms a preform, wherein the bifurcated outer wrap is folded to form stiffeners that may be oriented circumferentially or axially.

A method for producing a braided preform, includes the steps of: a) creating a braided sleeve from filler threads and braiding threads in a braiding process, for which purpose the filler threads and braiding threads are taken off thread accumulators, b) feeding a core to the braided sleeve, c) continuing the braiding process, wherein the core is advanced such that it is braided along its length, wherein, during step c), the take-off of at least one filler thread is blocked such that the at least one filler thread is pulled out of at least one section of the braided sleeve surrounding the core.

A method for producing a braided preform, includes the steps of: a) creating a braided sleeve from filler threads and braiding threads in a braiding process, for which purpose the filler threads and braiding threads are taken off thread accumulators, b) feeding a core to the braided sleeve, c) continuing the braiding process, wherein the core is advanced such that it is braided along its length, wherein, during step c), the take-off of at least one filler thread is blocked such that the at least one filler thread is pulled out of at least one section of the braided sleeve surrounding the core.

A fibrous preform for forming the fibrous reinforcement of a composite material part, the fibrous preform being made as a single piece and obtained by three-dimensional weaving, the preform including first and second skins and a longitudinal stiffening portion connecting the first to the second skin, the longitudinal stiffening portion forming a stiffening element of the part in the longitudinal direction. The preform has an intermediate portion extending in the longitudinal direction between two end portions. The longitudinal stiffening portion includes, in the intermediate portion, longitudinal non-woven threads or strands held together by first transverse threads or strands coming from the first skin and second transverse threads or strands coming from the second skin. In the end portions, the longitudinal threads or strands of the longitudinal stiffening portion are woven with the transverse threads or strands.

A fibrous preform for forming the fibrous reinforcement of a composite material part, the fibrous preform being made as a single piece and obtained by three-dimensional weaving, the preform including first and second skins and a longitudinal stiffening portion connecting the first to the second skin, the longitudinal stiffening portion forming a stiffening element of the part in the longitudinal direction. The preform has an intermediate portion extending in the longitudinal direction between two end portions. The longitudinal stiffening portion includes, in the intermediate portion, longitudinal non-woven threads or strands held together by first transverse threads or strands coming from the first skin and second transverse threads or strands coming from the second skin. In the end portions, the longitudinal threads or strands of the longitudinal stiffening portion are woven with the transverse threads or strands.

A process for producing a carbon sheet molding compound (SMC). An SMC manufacturing line including at least one conveyor line for laying up SMC resins on a carrier film is provided. A chopped carbon fiber which is evenly distributed using dehumidified supply air and using a pressurized air venturi apparatus which is used to debundle and randomize the carbon fibers, onto the resin on the carrier film as the carrier film moves along the conveyor.

A process for producing a carbon sheet molding compound (SMC). An SMC manufacturing line including at least one conveyor line for laying up SMC resins on a carrier film is provided. A chopped carbon fiber which is evenly distributed using dehumidified supply air and using a pressurized air venturi apparatus which is used to debundle and randomize the carbon fibers, onto the resin on the carrier film as the carrier film moves along the conveyor.

A method for repairing a part made of composite material includes producing a recessed section by removing the composite material at a damaged area, producing grooves extending on the two faces of the part from edges of the recessed section, producing orifices in the part opening out into the grooves, tree-dimensional weaving of a filling part fiber preforms including a central section having a shape corresponding to the shape of the recessed section and fiber bundles extending from the central section, placing the filling preforms respectively on either face of the part with the fiber bundles in the grooves on the faces of the part and in the orifices such that the fiber bundles open out into the grooves present on the opposite face of the part, impregnating the filling fiber preforms with a precursor resin of a matrix, transforming the resin into a matrix to obtain a filling part.

A composite article manufacturing facility comprising: a plurality of forming stations (1), each forming station being capable of forming pieces from a feedstock of a laminar reinforcement material; a plurality of lay-up stations (3), each lay-up station being capable of arranging a stack of the formed pieces in overlapping fashion; a transfer mechanism (2) configured to simultaneously transport formed portions from multiple ones of the forming stations towards multiple ones of the lay-up stations; a memory (93) storing a first sequence of pieces to be laid up at a first one of the lay-up stations and a second sequence of pieces to be laid up at a second one of the lay-up stations; and a controller (90) coupled to the forming stations, the lay-up stations and the transfer mechanism for controlling the operations thereof, the controller having access to the memory and being configured to, when a formed piece of the first sequence and a formed piece of the second sequence are loaded on the transfer mechanism, cause the transport mechanism to simultaneously transport them towards the first and second lay-up stations respectively.