A manufacturing process is provided during which a thrust reverser cascade is formed for an aircraft propulsion system. During the formation of the thrust reverser cascade, a first panel of material is stamped into a first corrugated body. A second panel of material is stamped into a second corrugated body. The first corrugated body is bonded to the second corrugated body.

A manufacturing process is provided during which a thrust reverser cascade is formed for an aircraft propulsion system. During the formation of the thrust reverser cascade, a first panel of material is stamped into a first corrugated body. A second panel of material is stamped into a second corrugated body. The first corrugated body is bonded to the second corrugated body.

Methods for forming carbon-based cellular structures and 3D structures that can be formed by use of the methods are described. Methods include shaping an essentially 2D sheet that includes an organic polymer to form a 3D precursor followed by heat treatment of the 3D precursor. Heat treatment carbonizes the polymer to form an amorphous carbon. A metal precursor solution can be applied to the 3D precursor, and subsequent heat treatment can form a metal carbide, metal nanoparticles, or other carbon-based materials on/in the cellular structures.

Methods for forming carbon-based cellular structures and 3D structures that can be formed by use of the methods are described. Methods include shaping an essentially 2D sheet that includes an organic polymer to form a 3D precursor followed by heat treatment of the 3D precursor. Heat treatment carbonizes the polymer to form an amorphous carbon. A metal precursor solution can be applied to the 3D precursor, and subsequent heat treatment can form a metal carbide, metal nanoparticles, or other carbon-based materials on/in the cellular structures.

A simple and inexpensive method for forming a vacuum bagging film includes formation of ribs, each by a sequence including placement of pressing members on the film, on either side of a region of the film, then translational displacement of at least a second of the pressing members, to reduce a distance mutually separating the pressing members, while exerting respective pressures on the film by each of the pressing members such that the pressing member in translation drives the film with it by friction, whereby the region of the film is deformed by buckling in forming the rib, then the stopping of the translational displacement, and then removal of the pressing members.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

A manufacturing method of middle member structure includes steps of applying an external force to a plate body to shape the plate body and form multiple recessed/raised structures and perforating the plate body to form multiple perforations misaligned from the recessed/raised structures so as to achieve a plate body with recessed/raised structures. The middle member structure is applicable to a vapor chamber to enhance the vapor-liquid circulation effect and the support for the internal chamber.