Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting a tool with sides made of a core material in a desired size and shape, disposing a preform of a fiber reinforced material that surrounds the tool, resulting in a lamina assembly comprising the preform and the tool, heating the tool and the preform, co-bonding the tool to the fiber reinforced material within the lamina assembly, and hardening the preform and the tool into a hybrid composite part.

The method for producing an assembly is a method for producing an assembly equipped with a member to be reinforced (20), a reinforcing member body (41), and a filler (42), wherein the reinforcing member body (41) has a pair of flanges (44) arranged spaced on the surface (20B) of the member to be reinforced (20), a web (45), and a connection portion (46) which connects the flanges (44) and the web (45) and forms a filler space (V) with the surface (20B). The method for producing an assembly includes a step for inserting a filler (42) into the filler space (V), a step for attaching a crack control member (43) to cover the end of the filler (42), a step for joining the flanges (44) and the member to be reinforced (20), and a step for curing at least the member to be reinforced (20).

A method of assembly for a gas turbine engine according to an example of the present disclosure includes, among other things, positioning an array of airfoils about an outer periphery of a hub, the hub being rotatable about an engine longitudinal axis of a gas turbine engine, the hub including a plurality of flanges, and each one of the airfoils including an airfoil section extending from a root section. An array of platforms are positioned about the outer periphery of the hub, each of the platforms including one or more slots defined by a plurality of platform flanges, and including the one or more slots receiving a respective one of the flanges of the hub. A plurality of retention pins are moved relative to the array of airfoils such each one of the retention pins extends through the flanges of the hub and through the plurality of platform flanges of a respective one of the platforms to mechanically attach a respective one of the platforms and the root section of a respective one of the airfoils to the hub. At least one of the airfoils and the platforms includes a plurality of composite layers that define an internal cavity, and includes a lattice structure in the internal cavity that extends between the plurality of composite layers.

Stringers and aircraft skin structures and related methods are disclosed. An example apparatus includes a skin structure and a support. The support includes a first surface, a second surface opposite the first surface, and a tapered edge extending from the first surface. The example apparatus includes a first material disposed between a first portion of the support and a first portion of the skin structure to couple the second surface of the support to the skin structure and a second material disposed between a second portion of the support and a second portion of the skin structure. The second material is different than the first material. The second portion of the support includes at least a portion of the tapered edge.

A system for making highly contoured composite stringers, including a flexible stringer assembly to support an uncured composite stringer; and a contoured mandrel to contour the uncured composite stringer into a highly contoured shape, wherein the contoured mandrel comprises one or more curvatures with a radius of 100 inches or less along at least one of an x, y, or z axis.

A method of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member. The radius filler element is formed of a permeable material. The method also includes absorbing resin from the composite base member into the permeable material of the radius filler element. The method additionally includes curing or solidifying the resin in the radius filler element and in the composite base member to form a cured composite structure in which the resin bonds the radius filler element to the composite base member.

A method of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member formed of dry fiber material comprised of reinforcing fibers. The radius filler element is formed of a radius filler material. The method also includes infusing resin into the dry fiber material, and chemically reacting the resin with the radius filler material to create a mixture of resin and radius filler material along side surface interfaces between the radius filler element and the composite base member. The method additionally includes curing or solidifying the resin, and allowing solvent in the resin to evaporate causing hardening of the mixture and bonding of the radius filler element to the composite base member, and resulting in a cured composite structure.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

A shear tie connector system for securing a frame component to a composite fuselage skin, which includes a shear tie connector and a fuselage mandrel, which defines a slot within which the shear tie connector is positioned.

A void between two or more composite laminate parts is filled by a composite laminate filler that is laid up and integral with at least one of the parts.