An assembly for a gas turbine engine according to an example of the present disclosure includes, among other things, an airfoil that has an airfoil section extending from a root section. The airfoil section extends between a leading edge and a trailing edge in a chordwise direction and extending between a tip portion and the root section in a radial direction. The airfoil section defines a pressure side and a suction side separated in a thickness direction. A platform is dimensioned to receive a retention pin to mount the platform to a rotatable hub. At least one of the airfoil and the platform includes a plurality of composite layers that define an internal cavity. A lattice structure in the internal cavity extends between the plurality of composite layers. The lattice structure has a plurality of branches that extend from a plurality of nodes.

Systems and methods are provided for fabricating gap fillers for composite parts. One exemplary system includes a controller that acquires a geometry for a gap filler that will occupy a volume at a joint between laminates of curable constituent material, subdivides the geometry of the gap filler into layers, and for each layer: identifies variations in width of the layer along a length of the gap filler, and generates instructions for trimming a web of curable constituent material to match the variations in width of the layer. The system also includes rollers that dispense webs of the curable constituent material, trimmers that trim the webs of the curable constituent material based on the instructions, and compaction rollers that compact the trimmed webs together to fabricate the gap filler.

A solid laminate stringer includes a base segment that forms a first generally trapezoidal cross section. The solid laminate stringer also includes a transition segment abutting the base segment, with concave sides that are continuous with the sides of the base segment. The solid laminate stringer also includes a top segment abutting the transition segment, where the top segment forms a second generally trapezoidal cross section with sides that are continuous with the concave sides of the transition segment. The solid laminate stringer also includes a first overwrap layer covering the top segment, the transition segment, and at least a portion of the base segment. The solid laminate stringer also includes a second overwrap layer overlapping at least a portion of the first overwrap layer covering the base segment.

A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.

A method of fabricating a composite material part having a body secured to at least one platform present at one end of the body, the method including using the fiber blank to form a preform for the part that is to be made by folding out segments of the second and third portions that are not interlinked with the first portion on opposite sides of the first portion, by shaping the folded-out segments of the second and third portions to form preform portions for a platform of the part to be fabricated, and by folding down the segment of the first portion in order to fill in the groove present in the gap between the second and third portions; and densifying the preform with a matrix in order to obtain a part made of composite material having at least one integrated platform.

Methods for manufacturing elongated structural elements are provided. Such methods provide composite material having optimal properties such as weight and strength which can be produced at much lower costs compared to conventional methods. Composite materials including such elements are also provided. In addition, commercial products incorporating such structural elements are provided.

A composite material has: a first layer in which a plurality of first sheets that are formed of a composite material including reinforced fibers and a resin are laminated; a second layer are laminated that each have a smaller thickness than any one of the first sheets and that are formed of a composite material including reinforced fibers and a resin; and a third layer that covers the surfaces of the second layer and the first layer and that is provided with a third layer which is formed of a composite material including reinforced fibers and a resin, wherein, when compared to the second sheet laminated on the side of the third layer, the other second sheets of the second layer occupy a larger area on the area of the surface of the first layer.

Roller assembly for forming adjacent curved surfaces in a composite gap filler member includes a first roller supported by a first support member, a second roller supported by a second support member and a support including a surface. First roller and the second roller are in contact with one another and in contact with the surface. With rotation of the first roller about a third axis and with at least one of the first roller or second roller moved relative to the other such that the first roller maintains contact with the second roller and the first roller and the second roller maintain contact with the surface, such that the first roller, second roller and the surface form an aperture having a first curved side having a first radius adjacent to a second curved side having a second radius wherein the first radius and second radius are unequal.

Apparatuses for creating layered tape composite structures include a frame, a source of first tape, and a first tape placement module configured to receive first tape and place the first tape on a layup surface as the frame translates along the layup surface. Some apparatuses further include a source of second tape, and a second tape placement module configured to receive second tape and place the second tape on the first tape as the frame moves along the layup surface. Methods for creating layered tape composite structures include supplying a first tape, and placing the first tape on a layup surface. Some methods further include supplying a second tape, and placing the second tape on the first tape on the layup surface.

A composite shaping apparatus includes at least one first roller that loads a prepreg with pressure, at least one second roller that loads the prepreg with pressure, and at least one motor that rotates at least one of the first roller or the second roller. The at least one first roller and the at least one second roller are rotated while at least one of rotation speed, roller diameter, or presence/absence of rotating power is made different between at least one of the first roller and at least one of the second roller.