An example method for curing a composite part includes placing the composite part onto a topside of a cure tool, and a bottom surface of the composite part contacts the topside of the cure tool and a top surface of the composite part is opposite the bottom surface of the composite part. The method also includes placing the cure tool and the composite part into an autoclave, using the autoclave to apply external heat to the cure tool and the composite part so that air flows over the top surface of the composite part to heat the top surface, and applying additional heat to a backside of the cure tool via radiation provided by at least one heating source of the cure tool, so as to reduce a temperature difference between the backside of the cure tool and the top surface of the composite part being cured.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

An apparatus includes a pressure vessel and a steerable heat source disposed within the pressure vessel. The apparatus also includes one or more control systems coupled to the steerable heat source. The one or more control systems are configured to direct supplemental heat toward a targeted region within the pressure vessel using the steerable heat source.

A method of manufacture of a composite aircraft article aerodynamic surface by forming the composite aircraft article aerodynamic surface on an aircraft article composite forming tool. The aircraft article composite forming tool includes a matrix laminate including an upper ply including a forming surface for forming the composite aircraft article aerodynamic surface. The upper ply of the aircraft article composite forming tool includes a nano filament structure embedded therein. A blank is conformed onto the aircraft article composite forming tool. The aircraft article is formed on the upper ply of the forming surface. The forming surface of the aircraft article composite forming tool is adapted to form an aerodynamic surface of the aircraft article. The blank is cured into the aircraft article. The composite aircraft article is finished.

Composite tooling systems and methods of manufacturing composite stringers of aircraft are provided herein. A composite tooling system includes a layup tool and an articulating stringer mandrel. The layup tool has a contoured surface with portions having different surface complexities. The articulating stringer mandrel includes two rigid mandrel elements and a cable. The first rigid mandrel element defines a first aperture, a first stringer surface, and a first bottom surface. The second rigid mandrel element is adjacent to the first rigid mandrel element and defines a second aperture, a second stringer surface, and a second bottom surface. A first length of the first rigid mandrel element cooperates with the surface complexity and a second length of the second rigid mandrel element cooperates with the surface complexity at the second rigid mandrel element so that a gap between the rigid mandrel elements does not exceed a predetermined gap threshold.

A method of manufacturing a sealed circuit card assembly includes disposing a circuit card assembly within a volume defined by a housing and at least partially filling the volume with a curable liquid such that the curable liquid encapsulates at least a circuit card. The method may also include curing the curable liquid to form a potted circuit card assembly and, after at least partially filling the volume with the curable liquid and after curing the curable liquid, vacuum impregnating the potted circuit card assembly with a sealant to seal any exposed interfaces or cracks to form the sealed circuit card assembly. Accordingly, the sealed circuit card assembly may include a first cured material encapsulating the circuit card of the circuit card assembly and a second cured material disposed within, for example, a porosity of the first cured material.

A method for forming a composite article includes adding an upper skin at least partially over a failsafe torque tube. The failsafe torque tube includes an inner tube and an outer tube. The method also includes adding a lower skin at least partially under the failsafe torque tube. The upper skin, the lower skin, and the outer tube are made of a composite material. The method also includes co-curing the upper skin, the lower skin, and the outer tube together to produce the composite article.

A method for curing a thermoset composite part, including placing the composite part within a heating assembly and using the heating assembly to heat the composite part; placing the heating assembly within a pressurization vessel and applying a consolidation pressure; removing the heating assembly from the pressurization vessel and using the heating assembly to cool down the composite part.

A method for molding a component. The method includes: providing a mold tool having a sprue and a cavity; heating the mold tool to a predetermined mold temperature; placing the heated mold tool into a pressure vessel; pouring a material through the sprue into the cavity of the heated mold tool; prior to complete polymerization of the material in the cavity of the heated mold tool, elevating an internal pressure of the pressure vessel to a predetermined pressure to apply a force to the material in the heated mold tool; completely polymerizing the material in the cavity in heated mold tool to form the molded component; and removing the molded component from the mold tool.