A high-altitude balloon manufacturing apparatus. The apparatus includes one or more extruders and one or more extrusion dies in fluid communication with the extruders. Each extrusion die is shaped to define one or more connector channels and one or more layering channels. The connector channels define extrudate flow paths between the layering channels.

For producing a dome-shaped element (2) provided with thermal protection for a solid propellant rocket engine, a coupling annular body (4) is arranged in a mold (5) and has a surface (20) that is clean and activated, by an atmospheric-pressure plasma treatment, before depositing a primer layer (26) and an adhesive layer (27) on the surface (20); ablative material is then automatically applied to the adhesive layer and to an area (17) of the mold (5) so as to form a series of superimposed layers (30).

Disclosed herein is a method. The method includes identifying a first location on a first part to place a first shim tab to form a first portion of a compound shim. The method also includes applying the first shim tab to the first location on the first part with an end-effector. The method also includes identifying a second location directly adjacent to the first location on the first part to place a second shim tab. The method also includes applying the second shim tab to the second location on the first part with the end-effector to form a second portion of the compound shim. The method also includes applying a third shim tab to the second shim tab at the second location to increase a thickness of the second portion of the compound shim.

A method of fabricating a high-altitude balloon. The method includes coextruding at least two adjacent continuous layers of extrudate, extrusion-bonding the layers of extrudate to one another along an edge of the sheets of extrudate to form a seam, and cooling the extrudate.

A high altitude balloon. A plurality of layers of coextruded extrudate are formed in a seamless sheet in a shape that defines a balloon envelope. Delaminator layers may be interposed between two or more of the layers of extrudate.

A polymer composite composition for use in high temperature applications such as furnaces, heat shields and aeronautical jet and rocket motors. In a particular application, the disclosed composition is applied to the manufacture of rocket motor cases, or parts thereof, to provide rigid thermal protection (RTP). The polymer composite composition comprises cyanate ester resin, fine lengths of carbon fibre and refractory filler material.

Co-extruded and extruded high-altitude balloons and apparatus and methods for manufacture. A high-altitude balloon has a plurality of layers of coextruded balloon panel extrudate, a first one of the layers extrusion-bonded to a second one of the layers along a first edge, the second one of the layers extrusion-bonded to a third one of the layers along a strip spaced apart from the first edge, extrusion-bonding of successive layers alternating between the first edge and the strip, the first one of the layers and the last one of the layers extrusion-bonded together along a second edge.

A sealing device for sealing edges of composite fiber components includes a strip feeder to apply a thermoplastic semifinished product to a cut edge of a composite fiber component, and an ultrasonic welding apparatus to thermoplastically or integrally join the thermoplastic semifinished product to the cut edge of the composite fiber component by ultrasonic welding.

A system for manufacturing a balloon envelope includes a table component and a sealing component. The sealing component includes a first level and a second lower level. The first level further includes first and second platforms. The first platform can provide a work area for sealing respective first and second sheets of material together to form a sealed edge and the second platform may provide a work area for sealing the second sheet of material and a third sheet of material together. The first, second, and third sheets of material respectively form first, second, and third gores of the balloon envelope. The sealing component may be configured to move along length of the first platform and to apply a heat seal to bond the first sheet of material to the second sheet material and form a sealed edge.

A single-skinned composite lattice sandwich structure includes a face sheet, fiber stringers, and at least one fiber tow arranged in a lattice structure separating the face sheet and fiber stringers. The face sheet and at least the fiber tow(s) forming the lattice may be interfused with a matrix to form a contiguous composite structure. The fiber stringers may be formed of various materials for imparting different structural properties to the sandwich structure, including carbon fiber for tensile strength and lightness, metallic or other rigid material for imparting overall structural rigidity, shape-changing material or actuated material for providing actuated deformation of the structure, and may also include sensors.