A method of forming a composite article includes constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion. The strand layer includes a plurality of strand segments traversing the interior portion and defining a first strand segment population density and a second strand segment population density. The preform is inserted into the mold cavity so that the interior portion of the preform is received in a molding region of the mold cavity. The molding region has a first thickness corresponding to the first strand segment population density and a second thickness corresponding to the second strand segment population density. Following the inserting, the mold is closed and the interior portion of the preform is compressed within the molding region. In the closed mold, the peripheral portion of the strand layer may be maintained in a loose state within the relief region.

A method of forming a composite article includes constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion. The strand layer includes a plurality of strand segments traversing the interior portion and defining a first strand segment population density and a second strand segment population density. The preform is inserted into the mold cavity so that the interior portion of the preform is received in a molding region of the mold cavity. The molding region has a first thickness corresponding to the first strand segment population density and a second thickness corresponding to the second strand segment population density. Following the inserting, the mold is closed and the interior portion of the preform is compressed within the molding region. In the closed mold, the peripheral portion of the strand layer may be maintained in a loose state within the relief region.

A method of introducing a rotor blade spar cap into a rotor blade shell for a rotor blade of a wind energy installation, a spar cap mold for manufacturing a rotor blade spar cap, a rotor blade comprising such a spar cap, and a wind energy installation including such a rotor blade. At least two strip-shaped spar cap elements are arranged on at least one substantially flat spar cap forming surface of the spar cap mold. The at least one spar cap forming surface extends along a longitudinal direction of the spar cap mold which corresponds to a longitudinal axis of the rotor blade. The spar cap elements are arranged on the at least one spar cap forming surface along the longitudinal direction and are connected to one another so as to form the rotor blade spar cap. The spar cap elements connected to one another are removed from the spar cap mold, are introduced into the rotor blade shell, and are connected to the rotor blade shell.

A method of introducing a rotor blade spar cap into a rotor blade shell for a rotor blade of a wind energy installation, a spar cap mold for manufacturing a rotor blade spar cap, a rotor blade comprising such a spar cap, and a wind energy installation including such a rotor blade. At least two strip-shaped spar cap elements are arranged on at least one substantially flat spar cap forming surface of the spar cap mold. The at least one spar cap forming surface extends along a longitudinal direction of the spar cap mold which corresponds to a longitudinal axis of the rotor blade. The spar cap elements are arranged on the at least one spar cap forming surface along the longitudinal direction and are connected to one another so as to form the rotor blade spar cap. The spar cap elements connected to one another are removed from the spar cap mold, are introduced into the rotor blade shell, and are connected to the rotor blade shell.

An aircraft panel assembly with a panel and a plurality of stiffeners on the panel is disclosed. Each stiffener has an attachment part attached to the panel and a structural part spaced apart from the panel. A rib foot beam crosses the stiffeners at a series of intersections. At each intersection the rib foot beam is located between the panel and the structural part of a respective one of the stiffeners.

A method for molding a composite pressure vessel liner to secure a boss to the liner is described. The method comprises providing a moldable liner having an end section with a neck and a port. A boss is positioned around the neck of the liner and the liner is heated and pressure is applied to mold the liner to form to the shape of the boss. The angle of the molded liner secures the boss in place around the liner and it is able to withstand high pressures. A tool for molding the liner and a method for using the tool is also described. The tool comprises a tool body and a pipe having external threads. The tool body abuts the liner and the boss. Winding the pipe exerts pressure on the liner, which when heated, forces the liner to mold to the shape of the boss.

An illustrative example composite leaf spring includes first and second bushing tubes near longitudinal ends. A ribbon of base material is wrapped at least partially around the first and second bushing tubes. The base material has a width that defines a width of the leaf spring. First portions of the base material are near the longitudinal ends and a second portion is between the first portions. The second portion is thicker than the first portions. A plurality of layers of a ribbon of tension material are wrapped around the base material. The tension material defines an outermost layer of the leaf spring. The tension material has warp strands in a longitudinal direction between the first and second longitudinal ends of the leaf spring and weft strands transverse to the warp strands. The warp strands establish a majority of a composition of the tension material.

An illustrative example composite leaf spring includes first and second bushing tubes near longitudinal ends. A ribbon of base material is wrapped at least partially around the first and second bushing tubes. The base material has a width that defines a width of the leaf spring. First portions of the base material are near the longitudinal ends and a second portion is between the first portions. The second portion is thicker than the first portions. A plurality of layers of a ribbon of tension material are wrapped around the base material. The tension material defines an outermost layer of the leaf spring. The tension material has warp strands in a longitudinal direction between the first and second longitudinal ends of the leaf spring and weft strands transverse to the warp strands. The warp strands establish a majority of a composition of the tension material.

A connecting element is configured to position a stabilizing member during the production of a component from a composite material, the connecting element having openings into which a melt composition in a molten state can flow, and the connecting element having at least one positioning device configured to position the stabilizing member on the connecting element. A component of a composite material has a cohesive, hardened melt composition, the connecting element described above, and at least one stabilizing member, the connecting element and the at least one stabilizing member being embedded in the melt composition, the melt composition reaching into the connecting element through the openings of the connecting element, and the at least one stabilizing member being positioned on the at least one positioning device of the connecting element.

A connecting element is configured to position a stabilizing member during the production of a component from a composite material, the connecting element having openings into which a melt composition in a molten state can flow, and the connecting element having at least one positioning device configured to position the stabilizing member on the connecting element. A component of a composite material has a cohesive, hardened melt composition, the connecting element described above, and at least one stabilizing member, the connecting element and the at least one stabilizing member being embedded in the melt composition, the melt composition reaching into the connecting element through the openings of the connecting element, and the at least one stabilizing member being positioned on the at least one positioning device of the connecting element.