Methods of manufacturing composite workpieces that include adding an expandable element to an internal volume of a constraining container proximate to a uncured composite workpiece supported on a rigid form, where the expandable element is configured to expand when a predetermined change is produced in an attribute of the expandable element; expanding the expandable element by producing the predetermined change in the attribute of the expandable element, so that an expansion of the expandable element applies pressure to the workpiece supported on the rigid form within the internal volume, and curing the composite workpiece while the resulting pressure is applied to the workpiece supported on the rigid form.

Implementations include a system including a preform fabrication apparatus and method for creating composite preforms through a process of determining a preform shape and number of layers required to assemble the preform and using a preform layer assembly apparatus to provide a number of functions such as receiving and holding a composite layer, shaping the composite layer, pressing composite layer onto a preform support structure, forming the composite layer into a preform shape, etc. Multiple composite layers may be picked up, held, shaped, and applied to a preform by the assembly apparatus. The assembly apparatus includes a flexible membrane settable to a deformable shape and a rigid state such that flexible membrane may be configured to be deformed into an assembly shape, which is then held in a rigid state. The flexible membrane may be used to apply pressure to an article to conform the article to the assembly shape.

Within examples, a mandrel is configured to be inserted into a cavity defined by an interior wall of a structural member to support the structural member during processing. The mandrel includes a first bladder containing a material, the material being capable of exhibiting granular jamming when air is removed from the first bladder. The mandrel further includes a second bladder configured to expand and apply a force to the first bladder. Systems and methods that relate to the mandrel are also described within examples.

The invention relates to a method and a molding core for producing a fiber composite component (34), in particular in aerospace, comprising the following method steps: introducing a core sleeve (9) into a molding tool (2) for establishing an outer geometry of a molding core (27) to be formed; filling the core sleeve (9) that is introduced with a vacuum-fixable filling material (21); applying a vacuum to the core sleeve (9) and consequently vacuum-fixing the filling material (21) for forming the molding core (27); and at least partly laying at least one semifinished fiber product (33a, 33b) on the molding core (27) that is formed, for the shaping of the fiber composite component (34) to be produced.

A flexible bladder can be expanded to insert a tool by implementing a tool assembly that includes an elongated hollow member including a hollow portion to receive at least one of a flexible bladder or a tool. An inlet member is attached to an end of the elongated hollow member. The inlet member receives at least one of the flexible bladder or the tool. A port is positioned on the elongated hollow member to apply vacuum inside the elongated hollow member.

A tooling element includes a flexible sleeve defining an interior cavity. The flexible sleeve includes a sealable access port extending through the flexible sleeve from the interior cavity to an exterior of the flexible sleeve. The tooling element further includes vacuum-packed tooling particulate disposed within and filling the interior cavity of the flexible sleeve.

The invention relates to a process for producing complex, mould-foamed rigid foam materials, more particularly of poly(meth)acrylimide (P(M)I) cores, preferably of polymethacrylimide (PMI) cores, which may be employed, for example, in carmaking or aircraft construction. A feature of the process is that through use of a particulate core during foam, it is possible to achieve an additional weight saving relative to foam materials or sandwich materials of the prior art.

A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

An applicator assembly for applying pressure to a composite structure includes an external frame, an applicator casing disposed substantially within the external frame, and an applicator disposed substantially within the applicator casing. The applicator casing includes a first membrane, and a first jamming material disposed within the first membrane. The applicator includes a second membrane, and a second jamming material disposed within said second membrane.