For the exact lateral continuous positioning of material plies on a forming tool, a positioning device is provided to position a material ply on a forming tool during a production of a fiber composite component, comprising a positioning unit for positioning the positioning device in relation to a surface of the forming tool, a movement unit for moving the positioning device along a predetermined movement route along the forming tool, a route position detection unit for detecting the current route position of the positioning device on the movement route, and a material ply positioning unit for positioning the material ply in a direction transverse to the movement direction in dependence on the current route position detected by the route position detection unit.

Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

Aircraft stringers having carbon fiber reinforced plastic (CFRP) material reinforced flanges are disclosed. An example stringer to be coupled to a skin of an aircraft comprises a flange. The flange includes a first portion of a first stiffening segment. The flange further includes a first portion of a second stiffening segment coupled to the first portion of the first stiffening segment. The flange further includes a CFRP reinforcement segment coupled to the first portion of the first stiffening segment and to the first portion of the second stiffening segment. The CFRP reinforcement segment strengthens the first portion of the first stiffening segment and the first portion of the second stiffening segment.

A door for a thrust reversal system, an aircraft with such a door, and a method for manufacturing a door of a thrust reversal system. The door comprises a wall formed from long fibers embedded in a thermoplastic resin matrix and a network of ribs overmolded on one of the faces of the wall. A propulsion assembly of an aircraft comprises a thrust reversal system having a plurality of such doors.

A core according to one aspect of the present disclosure is a core that is inserted into a space between a skin and a stringer in a step of integrally molding the skin and the stringer, the skin including fiber-reinforced resin, the stringer having a hat-shaped section that is open toward the skin. The core includes: a first die that extends along a longitudinal direction of the stringer and contacts the skin; a second die that extends along the longitudinal direction of the stringer, is adjacent to the first die, and contacts the skin; and a third die that extends along the longitudinal direction of the stringer, is located at an opposite side of the skin across the first die and the second die, and contacts both the first die and the second die.

An end effector for welding composite components includes an end effector housing and a welding member mounted to the end effector housing. The end effector further includes a leading roller mounted to the end effector housing forward of the welding member and at least one follower roller mounted to the end effector housing aft of the welding member. The end effector further includes at least one first cooling air jet positioned to direct a first stream of cooling air toward the at least one follower roller.

A tool for fabricating a control surface is disclosed. In various embodiments, the tool includes a first block defining a longitudinal direction running between a leading edge end and a trailing edge end; a first sidewall spaced a first lateral distance from the first block to form a first closeout channel running in the longitudinal direction between the first block and the first sidewall; and a second sidewall configured to form a second closeout channel running in the longitudinal direction, the second closeout channel disposed laterally opposite the tool from the first closeout channel.

A composite manufacturing system and method are provided. The composite manufacturing system comprises a press and a bladder. The press has an upper portion having a desired shape for a composite structure and a lower portion configured to receive layers of composite material. The bladder is associated with the upper portion of the press and is configured to reach a superplastic state when heated such that the bladder forms to the composite structure by applying heat and pressure to the layers of composite material. The bladder cools without appreciable shrinkage, applying a desired amount of pressure to the composite structure during the entire cooling cycle. Once one composite structure is formed using the bladder, the bladder may be reused to form similar structures.

Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

A thermoplastic surfacer for providing lightning strike protection to a composite component of an aircraft, methods of manufacturing the surfacer, and methods of applying the surfacer to a composite part. The thermoplastic surfacer includes a broadgood having a thermoplastic resin, one or more fillers embedded into the broadgood, and a lightning strike protection mesh or foil embedded into the broadgood. When applying the surfacer to a composite part of an aircraft, the method includes draping the surfacer on an at least partially unconsolidated composite part, consolidating the at least partially unconsolidated composite part by heating the part to a temperature at or above a melt temperature of a resins used in the part and in the surfacer, and filling at least one surface defect in the consolidated part using the thermoplastic polymer resin and milled fibers provided in the thermoplastic surfacer.