Apparatus and methods for sealing powder holes in additively manufactured parts are presented herein. Powder holes are co-printed to facilitate post processing sealing. Embodiments include co-printed caps, friction welded caps, rivets, silicone plugs, co-printed tangs, multiple micro holes, layup, and spin forming. By using one or more of the above techniques, powder holes can be sealed on additively manufactured parts.

A tool for curing and bonding a honeycomb stack with void filler. The tool has a first tool piece with a cavity for receiving layers of unfilled honeycomb material and a second tool piece with a cavity for receiving at least one layer of void-filled honeycomb. The tool also has a compression seal arrangement that creates gas-tight seals between the first tool piece, second tool piece, and a barrier layer positioned between them, with a further seal covering the cavity of the first tool piece to form a gas-tight sealed volume including the first cavity, a pressure plate to cover the cavity of the second tool piece to apply pressure to the void-filled honeycomb, with a further seal to cover the pressure plate to form a gas-tight sealed volume including the second cavity.

An airframe assembly for an aircraft includes a first airframe member having first and second skins with a large cell core and a solid insert joined therebetween. The solid insert has a side surface at least a portion of which is adjacent to the large cell core. The first airframe member has a first set of openings extending through the first skin, the solid insert and the second skin. The airframe assembly also includes a second airframe member having a second set of openings operable to be aligned with the first set of openings of the first airframe member. Each of a plurality of fasteners extends through one of the openings of the first set of openings and one of the openings of the second set of openings securably coupling the first airframe member to the second airframe member.

An airframe assembly for an aircraft. The airframe assembly includes a first airframe member having a first skin, a second skin, a large cell core joined between the first and second skins and a solid insert having a side surface. The solid insert is joined between the first and second skins such that at least a portion of the side surface is adjacent to the large cell core. The first skin has a first surface disposed opposite the solid insert. The airframe assembly also includes a second airframe member having a second surface. An adhesive joint is disposed between the first and second surfaces structurally bonding the first airframe member to the second airframe member such that the second airframe member is positioned opposite the solid insert.

Systems and methods are provided for acoustic paneling. One embodiment is a method for fabricating an acoustic panel. The method includes receiving a sheet of thermoplastic paper, stamping/conforming the sheet into rows that each comprise a three dimensional shape, and transforming the sheet into a multi-celled core. Transforming the sheet includes identifying fold lines separating the rows, folding the sheet at the fold lines in a pleat fold, thereby uniting upper surfaces of adjacent rows and uniting lower surfaces of adjacent rows; and compressing the rows of the folded sheet together in the presence of heat, causing adjacent rows to fuse together into cells. The method further includes applying a backing sheet to the core, and applying a facesheet to a surface of the core that includes openings which direct a portion of airflow across the facesheet into the cells, resulting in acoustic control.

A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.

Embodiments disclosed herein relate to polymer resins having a first thermoset and one or more additional components (e.g., a second thermoset and/or a thermoplastic), composite laminates including the same, methods of making and using the same, and composite laminate structures including the same.

An example method for manufacturing a multicellular structure for acoustic damping is described that includes applying a porogen material to a solid support, inserting a multicellular frame into the solid support and through the porogen material so as to fill cells of the multicellular frame with the porogen material, fusing the porogen material, removing the multicellular frame from the solid support, and the multicellular frame contains a suspended fused porogen network attached to walls of the cells of the multicellular frame. The method also includes applying a solution to the suspended fused porogen network in the cells of the multicellular frame to percolate the suspended fused porogen network, curing the solution, and removing the suspended fused porogen network from the multicellular frame resulting in porous septum membranes of the cured solution in cells of the multicellular frame.

A reinforced composite structure that includes multiple regions of different geometric configurations connected together by a transition region. The reinforced composite structure includes reinforcement fibers on at least a portion of the transition region.

An acoustic attenuation panel for a propulsion assembly includes an acoustic front skin having perforations, and a central structure formed from partitions arranged perpendicularly in order to make up cells, wherein the front skin and the central structure form the panel which is made as a single piece and is provided for directly covering a surface of an element of the propulsion assembly forming a rear skin which closes the cells of the central structure at the rear.