A method of forming a composite component comprising: forming a mandrel by additive manufacturing, the mandrel defining a shape for the component; providing a composite material around the mandrel to form a body of the component; curing the component body to produce the component, the mandrel forming a part of the component.

A method of forming a composite component comprising: forming a mandrel by additive manufacturing, the mandrel defining a shape for the component; providing a composite material around the mandrel to form a body of the component; curing the component body to produce the component, the mandrel forming a part of the component.

An installation for shaping a fiber preform as a body of revolution presenting a profile that varies in radial section, the installation including a storage mandrel for storing a fiber texture, follower rollers, and a mold in the form of a body of revolution on which the fiber texture is to be shaped by winding, the follower roller(s) being placed between the storage mandrel and the mold in the form of a body of revolution. The storage mandrel, each follower roller, and the mold present radii across their axial widths that vary to define outer surfaces having profiles in relief. A follower roller has sectors releasably fastened on the outer surface of the roller, each sector extending over a fraction of the circumference of the roller and over all or part of the axial width of the roller.

The separator production method in accordance with an embodiment of the present invention includes a coated article taking up step of taking up a separator original sheet by winding the separator original sheet on an outer peripheral surface of a core while oscillating the core in the rotation axis direction; a coated article winding off step of winding off the separator original sheet, which has been taken up in the coated article taking up step, from the core; and a transferring step of transferring the separator original sheet, which has been wound off in the coated article winding off step, such that a state of being distorted in a wavelike manner in the transverse direction is maintained.

The separator production method in accordance with an embodiment of the present invention includes a coated article taking up step of taking up a separator original sheet by winding the separator original sheet on an outer peripheral surface of a core while oscillating the core in the rotation axis direction; a coated article winding off step of winding off the separator original sheet, which has been taken up in the coated article taking up step, from the core; and a transferring step of transferring the separator original sheet, which has been wound off in the coated article winding off step, such that a state of being distorted in a wavelike manner in the transverse direction is maintained.

A method for producing a film and a film winding device are provided. When transferring of the film is slowed for winding of the film to be suspended and after winding of the film is suspended, transferring of the film is accelerated for winding of the film to be resumed. The film has a tension at a first level during a period extending from slowing of transferring of the film to suspending of winding of the film. Alternatively, the film has a tension at a first level during a period extending from a predetermined time point during a period during which winding of the film is suspended to a time point at which the accelerating starts. The first level of the tension is higher than a second level that the tension has immediately before slowing of the transferring of the film starts.

Methods and apparatus for manufacturing a thermoplastic structure include laying a first plurality of braided plies on a mandrel, and laying one or more unidirectional plies on the plurality of braided plies. A second plurality of braided plies is laid on the one or more unidirectional plies. The layup thereby forms a thermoplastic structure having combined braided and unidirectional plies.

According to an aspect, a method of assembling a mandrel includes assembling a plurality of members via interlocking features arranged at opposing edges of each member of the plurality of members to form a compartment, the assembled members having a collective outer surface that conforms to an inner surface of the spar. A support member is inserted into the compartment formed radially inward from the assembled members, the support member making contact with a portion of each member of the plurality of members.

Methods and systems are disclosed for manufacturing or reinforcing of any length, shape, size, and any thickness pipe with a plurality of layers comprising at least a first reinforcement sheet, a pre-designed and localized resin-fortified Core, and a second reinforcement sheet. The Core includes A-regions which are designed to absorb less resin, and B-regions which are designed to absorb more resin. For reinforcing a pipe, a first reinforcement sheet is placed over the inside and/or the outside surface of the pipe. A pre-designed and localized resin-fortified Core is placed over and adhered to the first reinforcement sheet. Subsequently a second reinforcement sheet is placed over the surface of the Core, such that the Core stays between the first and the second reinforcement sheet. Next, the resin-saturated sheets and Core are cureddepending on the type of resinby partial or complete exposure to ambient temperature, to heat, or to light.

A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.