A multilayer core molding method includes an upstream process of molding using an upstream process molding apparatus, which includes a first upstream process mold including a first upstream process mold cavity surface, and a second upstream process mold including a second upstream process mold cavity surface. The upstream process includes an inner core arrangement step and a covering step to obtain an intermediate molded body, which includes the inner core, and the unvulcanized or semi-vulcanized first outer core material covering only part of a surface of the inner core and integrated with the inner core.

A laying die, for picking up and laying of substrates, comprising an elastically deformable substrate receiving structure providing an engagement surface for releasable receiving of substrates, an attaching element comprising a gas channel for providing positively or negatively pressurized gas for picking up and blowing off the substrates, and a carrier body made from elastically deformable material and sandwiched between the substrate receiving structure and the attaching element which is arranged to distribute the positively or negatively pressurized gas over the carrier body. The carrier body comprises breakthroughs to transfer the pressurized gas from the attaching element to the substrate receiving structure that comprises an elastically deformable distribution plate to distribute the positively or negatively pressurized gas over the engagement surface. Also, a laying device which changes the position and/or orientation of substrates to predetermined values can comprise the laying die and a method for manufacturing the laying die.

A laying die, for picking up and laying of substrates, comprising an elastically deformable substrate receiving structure providing an engagement surface for releasable receiving of substrates, an attaching element comprising a gas channel for providing positively or negatively pressurized gas for picking up and blowing off the substrates, and a carrier body made from elastically deformable material and sandwiched between the substrate receiving structure and the attaching element which is arranged to distribute the positively or negatively pressurized gas over the carrier body. The carrier body comprises breakthroughs to transfer the pressurized gas from the attaching element to the substrate receiving structure that comprises an elastically deformable distribution plate to distribute the positively or negatively pressurized gas over the engagement surface. Also, a laying device which changes the position and/or orientation of substrates to predetermined values can comprise the laying die and a method for manufacturing the laying die.

A method and apparatus for constructing a tubular assembly 40 comprising an inner portion (24) and a further portion (23) surrounding the inner portion. The inner portion (24) comprises reinforcement (37) and the further portion (23) being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus comprises an assembly station (220) comprising a wall (253). The apparatus comprises means for advancing the inner portion (21) along a first path (231) extending passed the wall (253), and means for advancing the strip (50) along a second path (232) and causing the strip to encircle the wall (253) and thereby wrap about and surround the inner portion (21). The apparatus further comprises means (321) for introducing resinous binder into the reinforcement (37) as the strip (50) is being wrapped about the inner portion (21).

Systems and methods are provided for vacuum handling of composite parts. One embodiment is a method for picking up, placing, and compacting an object. The method includes covering a part of an object with an impermeable membrane, applying a negative pressure via an end effector that is sufficient to offset any air leaks between a first portion of the impermeable membrane and the object, thereby forming a suction hold that secures the object to the impermeable membrane, and transporting the object to a rigid tool while the suction hold is retained. The method further comprises applying a negative pressure via the end effector that offsets air leaks between a second portion of the impermeable membrane and the rigid tool, thereby forming a suction hold that compacts the object to the rigid tool.

A method for use in forming a composite structure that includes dispensing a first sheet of composite material, cutting the first sheet of composite material to form one of a plurality of plies of composite material, and providing the plurality of plies of composite material to a forming tool one at a time in a ply laydown sequence. A first sequential ply in the ply laydown sequence is provided, and then a second sequential ply in the ply laydown sequence is automatically provided after the first sequential ply has been provided.

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a flange forming device at the ply of material on the forming tool, the flange forming device including an inflatable contact element pressurized to define a deformable contact surface, applying, by the deformable contact surface, the ply of material onto the forming tool with a predetermined pressure, wherein the deformable contact surface is moved across the forming tool, and wherein the inflatable contact element is configured to maintain the predetermined pressure as the deformable contact surface transitions from the web surface to the at least one flange surface.

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.

Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.