A method of forming a rotor blade, including forming at least one of a partial upper skin, a partial lower skin, and a partial support network using an additive manufacturing process; and forming a first receptacle in at least a one of the partial upper skin, the partial lower skin, and the partial support network using the additive manufacturing process. The first receptacle is configured to receive of at least one of an electronic component and a mechanical component. In some embodiments, there is a method of manufacturing a rotor blade that includes forming a first locating receptacle in at least one of the upper skin, the lower skin, and the support network using the additive manufacturing process; and positioning at least one of the upper skin, the lower skin, and the support network in a desired position on a fixture based, in part, on the first locating receptacle.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

A co-curable thermoset acoustic liner and method of forming the same includes a sound attenuating core having a plurality of core cells. An inner face sheet having a plurality of face sheet apertures is coupled to the core by an inner thermoset adhesive sheet, which has a plurality of adhesive sheet apertures. Each of the plurality of adhesive sheet apertures is aligned within a corresponding one of the plurality of face sheet apertures so that the plurality of core cells are placed in fluid communication with airflow over the inner face sheet to create a Single Degree of Freedom (SDOF) acoustic liner.

A composite construction, such as, in particular, a composite plate having a sandwich-type construction, has two outer layers which are mutually opposed in parallel and a foam material completely filling the space between the outer layers at least in some regions. The outer layers are interconnected by means of spacers, and the spacers are connected to the outer layers via a cured plastics material.

A method for reinforcing a substrate or textile of a core structure of a component with the following method steps: a continuous semi-finished product is fed, via a feed means, into a cartridge of a conveying means which comprises a plurality of cartridges; the continuous semi-finished product is cut to length using a cutting means in order to produce a cut, reinforcing semi-finished product which is received in the cartridge; the cartridge is conveyed to a machining means; the cut, reinforcing semi-finished product is sharpened using the machining means; the cartridge is conveyed to a textile or substrate to be reinforced of a core structure; and the sharpened semi-finished product is shot into the textile or substrate of a core structure by a stud-shooting means.

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.

A core stiffened panel includes first and second skins having 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 and may be joined to the large cell core. The first skin, the second skin and the solid insert may be formed from composite materials such as carbon composite materials and preferably have generally matching coefficients of thermal expansion.

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.

A method for manufacturing an aeronautical sandwich panel with a honeycomb core and results in a core sealed to prevent infused resin from entering into the honeycomb core open cells while improving its mechanical properties, especially for curved or highly curved panels. In further embodiments, the invention proposes the automation of this process.

Production process of a composite product (1) comprising a core (2), a first layer (3) comprising a sheet impregnated with a solid polyurethane material, and a polymer-based film (7) applied to the first layer (3), wherein the process comprises: producing a semi-finished product comprising the core (2) and the sheet impregnated by a liquid mixture precursor of the solid polyurethane material; adhering the film (7) to a first half-mould (11) by applying a depression between the film (7) and the half-mould (11); pressing two half-moulds (11, 12) against each other with the semi-finished product interposed between two shaping surfaces (13), so that the film (7) comes into contact with the liquid mixture; with the semi-finished product in the mould, thermosetting the liquid mixture to transform it into the polyurethane solid material so that the film (7) firmly adheres to the first layer (3) and thus producing the composite product (1).