A bionic nested structure fiber composite material includes a first fiber resin layer and a second fiber resin layer which are arranged in parallel, the first fiber resin layer and the second fiber resin layer are formed by a fiber bundle infiltrated with resin, and a bonded fiber unit is arranged between the first fiber resin layer and the second fiber resin layer, the bonded fiber unit are evenly distributed in a radial direction and a weft direction, the bonded fiber unit includes an inner core layer bonded fiber bundle, a middle core layer bonded fiber bundle and an outer core layer bonded fiber bundle, and the bonded fiber unit is performed 3D integrated layer-by-layer inner and outer nesting-and-weaving to form bionic nested structure.

A panel is disclosed, including a first facesheet, a second face sheet, and a plurality of pultrusion-formed web structures. Each web structure has a middle support portion, a first end portion, and a second end portion. The first end portion of each web structure is attached to the first facesheet and the second end portion of each web structure is attached to the second facesheet. The middle support portion, first end portion, and second end portion of each web structure form a single monolithic structure.

A method for forming a fiber-reinforced thermoplastic control surface may comprise: stacking plies of thermoplastic composite sheets to a first desired thickness to form a first skin; stacking plies of thermoplastic composite sheets to a second desired thickness to form a second skin; forming the first skin in a first contour; forming the second skin in a second contour; forming a stiffening member including a thermoplastic resin, the stiffening member including a shape having a plurality of peaks and troughs; assembling the stiffening member between the first skin and the second skin; and joining the stiffening member to the first skin and the second skin.

Coextruded articles comprising first and second layers each having first and second opposed major surfaces and between the first and second layers a series of first walls providing a series of microchannels, and methods for making the same. Embodiment of coextruded articles described herein are useful, for example, in cushioning applications where high levels of compression are desired.

Multi-body interpenetrating lattices comprise two or more lattices that interlace or interpenetrate through the same volume without any direct physical connection to each other, wherein energy transfer is controlled by surface interactions. As a result, multifunctional or composite-like responses can be achieved by additive manufacturing of the interpenetrating lattices, even with only a single print material, with programmable interface-dominated properties. As a result, the interpenetrating lattices can have unique mechanical properties, including improved toughness, multi-stable/negative stiffness, and electromechanical coupling.

Coextruded articles comprising first and second layers each having first and second opposed major surfaces and between the first and second layers a series of first walls providing a series of microchannels, and methods for making the same. Embodiment of coextruded articles described herein are useful, for example, in cushioning applications where high levels of compression are desired.

A method for forming a fiber-reinforced thermoplastic control surface includes forming first and second skins from a fiber-reinforced thermoplastic resin. The method further includes overmolding fiber-reinforced thermoplastic features onto the first skin and/or second skin, including stiffener structures, sidewalls, and/or hinges. The method further comprises welding or consolidating the first and second skins together, along with the associated internal features overmolded thereon to form a single-piece, stiffened, fiber-reinforced thermoplastic control surface.

The invention relates to a method for manufacturing a box-shaped monolithic structure with a cavity by curing a fiber-reinforced prepreg material. The method comprises using two or more elongated and internally hollow support tools which have a complementary form to that of the cavities to be manufactured, and a composition based on reinforcement material and polymer suitable to allow the passage from a rigid state to a flexible elastomeric state and vice versa in response to heating/cooling down. In the rigid state, the support tools allow the direct lamination of the prepreg material on their external walls and are configured to set the flexible elastomeric state at a temperature lower than the curing temperature and higher than 50° C. During the curing operation, the curing pressure is applied both outside the structure being formed and inside the support tools, whose walls have become flexible, to push on the prepreg material to be cured.

A panel is disclosed, including a first facesheet, a second face sheet, and a plurality of pultrusion-formed web structures. Each web structure has a middle support portion, a first end portion, and a second end portion. The first end portion of each web structure is attached to the first facesheet and the second end portion of each web structure is attached to the second facesheet. The middle support portion, first end portion, and second end portion of each web structure form a single monolithic structure.

A method of additively manufacturing a spacecraft panel includes printing a first skin and a second skin, spaced apart from the first skin. The method further includes printing a first truss structure connecting the first skin to the second skin.