Systems and methods are provided for fabricating composite parts. One embodiment is a method of forming a composite part. The method includes laying up opposing composite facesheets, placing a viscous material between the facesheets, increasing a distance between the facesheets, and solidifying the facesheets and the viscous material into an integral composite part.

In one aspect of the present subject matter, a method of forming a linear panel includes drawing a multi-layer panel material assembly having differing inner and outer material layers along a processing path. The method also includes heating the panel material assembly. In addition, the method includes forming the heated panel material assembly into a desired shape as the assembly is drawn along the processing path. Additionally, in another aspect of the present subject matter, a linear panel includes a body formed from a multi-layer panel material assembly having differing inner and outer material layers.

The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

A method of forming a sandwich structure including at least partially filling an open volume of an open cellular core with a sacrificial mold material, consolidating the sacrificial mold material to form a sacrificial mold, laying up a composite facesheet on each of at least two surfaces of the open cellular core, co-curing the composite facesheets by applying a consolidation temperature and a compaction pressure to the composite facesheets to form the sandwich structure, and removing the sacrificial mold. The compaction pressure is greater than a compressive strength of the open cellular core and less than a combined compressive strength of the open cellular core and the sacrificial mold.

A panel for a vehicle includes a core formed from fibers and a thermoset resin. The panel also includes a first barrier layer positioned on a first side of the core and a second barrier layer positioned on a second side of the core, opposite the first side. Each of the first and second barrier layers is configured to block flow of the thermoset resin from the core during a panel forming process.

A fire resistant panel member and a related method for producing a fire resistant panel member where the panel member includes a first layer, a second layer covering at least a portion of a surface of the first layer, the first and second layers each comprising a pigmented polyester resin and a first organic peroxide, a third layer covering at least a portion of a surface of the second layer, a substantially rigid core member covering at least a portion of a surface of the third layer, and a fourth layer covering at least a portion of a surface of the core member, the third and fourth layers each comprising a polyester resin, a flame retardant, a second organic peroxide, and a fiber material, wherein the panel member is configured to have an ASTM E84 Class I fire and smoke rating.

Disclosed are a sandwich panel capable of being advantageously applied to a body wearable device, and a method of manufacturing the same. The sandwich panel includes: a core; and face sheets attached to both surfaces of the core, wherein the face sheet is made of a two-dimensional auxetic material. The core has a neutral surface in accordance with bending moment and is made of a porous material. The face sheet is made of metal, polymer, ceramic, or a composite material, and has higher density, strength, and rigidity than the core. The method includes: processing face sheets; and attaching the face sheets to both surfaces of a core, wherein the face sheet is processed to have a two-dimensional auxetic structure.

A process for producing a sandwich component. A first covering layer is formed on a molding surface of a molding tool; a core is produced by building up a cell structure having a multiplicity of cells in a thickness direction on the first covering layer via an additive production process; and a second covering layer is formed on a deposition surface of the core, the surface being situated on the opposite side from the first covering layer. A core for a sandwich component is furthermore described, as is a sandwich component.

An acoustic panel comprising a cellular structure, such as a honeycomb structure, having cells that open at least onto a first frontal face of the structure. The panel comprises a capsular skin which is fastened to the first frontal face of the cellular structure next to a plurality of cells. The capsular skin including a continuous layer of material, in one piece, forming capsules that extend into the cellular structure. At least one channel is provided at the apex of each capsule for the passage of acoustic waves. Such a panel effectively attenuates the noise of aircraft engines, in particular, the low frequencies. It is extremely easy to manufacture industrially, the capsular skin being able to be obtained by molding with polymerization in situ, the polymerizable material then adhering to the cellular structure while it polymerizes.

A panel including an outer face sheet; an inner face sheet; a foam disposed between the outer face sheet and the inner face sheet; and a core structure (e.g., a stringer comprising a hat structure) between the foam and the inner face sheet; and between the foam and the outer face sheet. The core structure is protected from impact damage and increases flexural stiffness of the panel on an aircraft wing.