A tool provided that individually creates three-dimensional structural elements which are sequentially positioned into formation of a shaped object.

A structural component, in particular for an aircraft, spacecraft or rocket, has a ply of fiber reinforced polymer; a first carbon nanotube mat; and a metallic layer, wherein the carbon nanotube mat and the metallic layer are arranged on the ply of fiber reinforced polymer to form a hybrid lightning strike protection layer. A component for manufacturing such a structural component, a method for manufacturing a component of this type, a method for manufacturing a structural component and an aircraft or spacecraft with such a structural component are described.

The present invention provides a glossy finish sandwich composite, comprising face sheet as skin element and a core element; wherein, the skin element is a composite selected from the group consisting of inorganic industrial waste particulates reinforced polymeric composite; fibres reinforced polymeric composite; and fibres and particulate reinforced hybrid polymer composite; wherein, the core element is selected from the group consisting of polyurethane foam and wastes reinforced polymeric material. The present invention also provides a novel process for developing glossy finish high performance hybrid sandwich composite(s). Moreover, the sandwich composite(s) of the present invention are unique materials which have versatile applications in wider spectrum of utility in sustainable manner and address issues on waste management, effective utilisation of renewable resources and agro-wastes.

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.

A method of manufacturing a flywheel comprising: forming a first hollow cylinder from glass fibre composite with magnetic particles dispersed through at least part of the cylinder; curing said first cylinder in a first curing step; forming a second hollow cylinder from carbon fibre composite; and curing said second hollow cylinder in a second curing step.

The present disclosure generally relates to a method for dispensing material from a roll. The method monitors the weight of a first material roll using a load cell attached to a frame holding the first material roll. The method dispenses material from the first material roll. The method determines, based on at least the weight of the first material roll, when to remove a second material roll from a refrigerator or freezer to reduce the amount of time between the thawing of the second roll and replacing the first roll with the second roll. Also disclosed is an apparatus for dispensing the material from the roll.

The present invention relates to a method of molding a component (1) having one or more features (5). At least one fibrous substrate (7) is located in a mold (31, 33). A matrix-forming material (29) is also provided in the mold (31, 33). Heat is applied to melt the matrix-forming material (29) to form a matrix (9) and to integrally mold said one or more features (5).

A novel method of fabricating carbon nanotube sheet scrolled fiber and fiber tows (carbon, graphite, glass, natural polymer, synthetic polymer, metallic, silicon carbide, Kevlar, etc.) in composites with improved interfacial shear strength, compressive strength, yield strength, stiffness and toughness has been reported. Single or multiple layers of carbon nanotube sheet, with a bias/wrapping angle of 0° and 90°, has been scrolled around single fiber and fibers tows to improve the above mentioned mechanical properties of the matrix surrounding the fiber. Other common methods of growing CNTs directly on the fibers actually damage the fiber surface during the required precursor deposition and CNTs growth process. This demonstrated solid-state method overcomes such known problems. The CNTs sheet scrolled fiber is embedded into the polymer matrix exhibits significant (80%) increase in interfacial shear strength, compressive strength and toughness.

Systems and methods are provided for dynamically altering the shape of a forming tool for a composite part during forming. An exemplary forming tool includes a main body that holds a first portion of a multi-layer laminate, and a platform that holds a second portion of the laminate aligned with the first portion. The forming tool also includes a biasing device that repositions the second portion with respect to the first portion during forming of the laminate, causing shear stresses between the layers of the laminate.

A form for a vehicle component including a commingled fiber bundle laid out in a two-dimensional base layer that defines a shape of the form, a successive layer formed with the commingled fiber bundle in contact with the two-dimensional layer, and at least one of electrical conductive wiring, sensor, light emitting diode (LED), antenna, radio frequency identification chip, or a printed circuit board stitched to the successive layer. The comingled fiber bundle is composed of a reinforcement fiber being glass fibers, aramid fibers, carbon fibers, or a combination thereof.