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 variety of molding profiles and related methods of manufacturing and installing the molding profiles are described. An example molding includes: an extruded profile of unitary construction including: a substantially planar central portion; at least one downwardly depending substantially planar wing; at least one hinge section joining the at least one wing to the central portion; and a pair of vertical legs depending from a bottom surface of the central portion, wherein the central portion, the at least one wing, and the vertical legs are formed of a first material, wherein the at least one hinge section is formed of a second material, and wherein the second material is more flexible than the first material.

A component part for a motor vehicle having a hollow profile portion of a fiber-reinforced plastic and a load introduction element of a metal material. The hollow profile portion and the load introduction element are connected in a common connection portion via a nondetachable, glued plug-in connection in which an end portion of the load introduction element and an end portion of the hollow profile portion engage in one another by positive engagement. The end portion of the load introduction element has a spline with teeth extending in longitudinal direction of the common connection portion so that the stiffness of the end portion of the load introduction element reduced in longitudinal direction of the common connection portion.

A method includes molding an outer impact beam made of carbon fiber reinforced plastics (CFRP) and separately molding an inner impact beam made of CFRP. The outer impact beam and the inner impact beam are coupled to each other to form an impact beam and the impact beam is coupled to an inner panel of a vehicle door.

A roller assembly for forming adjacent curved surfaces in a composite gap filler member includes a first roller supported by a first support member wherein the first roller rotates relative to the first support member about a first axis of rotation. A second roller is supported by a second support member wherein the second roller rotates relative to the second support member about a second axis of rotation. First support member is rotatable about a third axis of rotation and the third axis of rotation extends in a direction transverse to the first axis of rotation. Second support member is rotatable about a fourth axis of rotation. The fourth axis of rotation extends in a direction transverse to the second axis of rotation.

A system for manufacturing a composite assembly includes a first mandrel, a second mandrel, a first wrap plate, and a second wrap plate. The first wrap plate and the second wrap plate are positionable in side-by-side relation for receiving a wrap material stack. The first wrap plate and/or the second wrap plate are translatable to a wrap plate open position defining a wrap plate gap between the first and second wrap plate surface edge for receiving a bladder. The second mandrel is translatable to a mandrel open position defining a mandrel gap between the first and second mandrel surface edge. The wrap plate gap and the mandrel gap are configured to receive the wrap material stack formed around a bladder. The first and second wrap plate are configured to fold a first and second material stack base portion into overlapping relation with each other on the bladder top.

Composite profiles, such as rotor blades, airfoils, I-beams, and box beams having non-uniform cross sections, and a system, method and process for pultrusion of composite profiles. The pultrusion of a heavier or thicker cross section portion of the composite profile is performed in-line and upstream from pultrusion of a thinner or lighter portion of the pultruded profile using a separate die for the thicker portion of the cross section, or leading edge slug, in order to optimize the processing conditions, productivity, and consistency of the composite profiles.

A pultrusion device and method are provided for producing a fiber-reinforced continuous section which has a second cross-sectional profile that is discontinuous in a direction of pultrusion with a press forming device for shaping the continuous section. The press forming device includes a first shaping device for producing the continuous section with a continuous cross-sectional profile and a second shaping device, which follows on from the first shaping device in the direction of pultrusion, for shaping the second discontinuous cross-sectional profile of the continuous section. A punching tool is arranged between the first shaping device and the second shaping device and is designed to bring about a local change in shape of the continuous cross-sectional profile, at least in a defined portion of the continuous section, in order to produce a first discontinuous cross-sectional profile of the continuous section.

A method is provided for manufacturing a composite body. A first longitudinal portion of a continuous length of prepreg material is shaped using a first die of a compression molding tool to provide a shaped first longitudinal portion of the continuous length of prepreg material. The shaped first longitudinal portion is consolidated using the compression molding tool to provide a first portion of the composite body. The first portion of the composite body is moved out of the compression molding tool. The first die is swapped for a replacement first die. A second longitudinal portion of the continuous length of prepreg material is shaped using the replacement first die of the compression molding tool to provide a shaped second longitudinal portion of the continuous length of prepreg material. The shaped second longitudinal portion is consolidated using the compression molding tool to provide a second portion of the composite body.

An elongate thermoplastic composite member is fabricated by a continuous molding process. A pre-consolidated thermoplastic laminate is softened by heating it to a temperature below its melting layup, and is fed substantially continuously through multiple sets of tool dies. The tool dies incrementally mold portions of softened laminate over a mandrel to form the laminate into a shape having a closed cross section.