Systems and methods are provided for a caul plate having a feature for removal. One embodiment is a caul plate for forming a composite part. The caul plate includes a body that includes a lower surface which faces the composite part, and an upper surface that is opposite to the lower surface. The caul plate also includes a groove in the upper surface to accept a tool to slide the caul plate laterally from the composite part.

A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

A joint structure includes a reinforcement portion that is formed by joining a composite material and a reinforcing material through an adhesive. The composite material includes a plate portion that is formed by laminating a plurality of fiber sheets, and a raised portion that is formed by laminating a plurality of fiber sheets in addition to the plurality of fiber sheets of the plate portion, and surfaces of the plate portion and the raised portion are covered with a single fiber sheet. The reinforcement portion includes the raised portion and the reinforcing material that is bonded to the raised portion through an adhesive. A first boundary between the plate portion and the raised portion and a second boundary between the raised portion and the reinforcing material are located at different positions in an in-plane direction of a laminated interface between the fiber sheets that are laminated.

Provided are methods of forming stiffened stringer panels with integrated plank structures. A skin member having an inner surface is provided. A plank is positioned onto the inner surface of the skin member. The plank extends from a first side to a second side, and each laminate ply of the set of layered laminate plies is sized to form a geometric profile for each of the first side and the second side. Each laminate ply of the set of layered laminate plies is arranged to extend from the first side to the second side. A stringer is placed onto a support tool. The support tool, and the stringer thereon, is positioned upon an uppermost laminate ply of the set of layered laminate plies. The skin member, the plank, and the stringer are joined.

A method for manufacturing an electrically conductive composite material includes obtaining a composite material which includes a thermoplastic matrix and short carbon fibers and is free of carbon nanotubes, preheating a furnace until a predetermined target temperature is reached, inserting the composite material into the preheated furnace once the target temperature has been reached, and heating the composite material in the furnace at the predetermined target temperature which is kept constant for a predetermined duration.

A method, apparatus, system, and computer program product for fabricating a composite part. Composite materials are laid up on a mandrel. A caul is placed over the composite materials laid up on the mandrel. An inner mold line of the caul is sized to an outer surface of the composite materials in a cured state. The composite materials laid up on the mandrel with the caul over the composite materials is cured to form the composite part. The composite materials expand to the inner mold line of the caul during curing of the composite materials to form the composite part.

Aircraft window assemblies and methods. The aircraft window assemblies comprise a window frame configured to support a window pane on an aircraft skin about a window aperture defined in an aircraft skin. The window frame includes a base formed of a continuous fiber reinforced thermoplastic composite and at least one overmolded feature molded to the base. The base defines a central aperture and includes circumferential flange portion configured to support the base on the aircraft skin surrounding the window aperture and a skirt portion extending inwardly from the circumferential flange portion and surrounding the central aperture. The skirt portion is non-planar with the circumferential flange portion and comprises a support surface for the window pane. The methods comprise forming the window frame, which comprises stamp-forming the base of the window frame from a continuous fiber reinforced thermoplastic composite sheet and overmolding the at least one overmolded feature to the base.

A joining method and assembly for an aircraft. To improve the characteristics or permit hitherto impossible connections between thermoplastic and thermoset components, a multi-material joining method is disclosed in which a thermoplastic connecting region is formed on the thermoplastic component. The connecting region is connected to the thermoset component by interdiffusion. For this purpose, the uncured second component is brought into contact with the connecting region and heat is supplied. An interdiffusion layer is formed which fixedly connects the second component and the connecting region to one another and thus joins the first component to the second component.

A method for repairing a composite structure, includes creating a repair cavity in a composite structure, placing foamable media in the repair cavity, placing a replacement skin over the repair cavity, and expanding the foamable media placed in the repair cavity.

Process for manufacturing inflatable bodies capable of assuming a desired complexly curved shape comprising two, around their circumference hermetically bonded opposing membranes (3, 4), which are internally linked by a plurality of link tapes (1), which tapes are bonded at an exact length and inclination angle at an exactly determined position. By numerical instructions, a continuous tape is fed and bonded alternately on the insides of the membranes by means of a roboticized tape positioning head, creating bond lines (2) between the tape and a membrane. Any fold occurring through local inclination, or planar angle variation of the tape relative to a membrane is kept between two bond lines on a membrane (3,4). A roboticized tape positioning and bonding head inside, and a bond activation head outside of a membrane can position relative to a membrane (3,4) by means of printed positioning marks, optical and proximity sensors to create the bond lines (2).