A composite panel assembly and method of forming the same includes a core, an inner skin coupled to a first side of the core, and an outer skin coupled to a second side of the core. A peripheral edge including portions of the core, the inner skin, and the outer skin, is compressed to close a path into the core.

A method for fabricating a stiffened panel. Layers of composite material are placed on a surface of an inner-mold-line tool having protrusions that extend from the surface of the inner-mold-line tool. The layers of composite material laid-up on the surface of the inner-mold-line tool are compacted to form compacted layers of composite material. The compacted layers of composite material are cured to form an inner-mold-line layer having corresponding protrusions. The inner-mold-line layer is joined to an outer-mold-line layer.

Techniques for inlaying a composite material within a tooling shell are disclosed. In one aspect, an additively manufactured tooling shell is provided, into which a composite material is inlaid and cured. A surface of the tooling shell is provided with indentations or another mechanism to enable adherence between the composite material and the tooling shell. The resulting integrated structure is used as a component in a transport structure.

A method of repairing an acoustic core cell of an acoustic sandwich panel is provided. The method comprises inserting a core repair splice adjacent to a number of damaged walls of the acoustic core cell of the acoustic sandwich panel, nesting the core repair splice onto the number of damaged walls, and bonding the core repair splice to the number of damaged walls and thereby to repair the acoustic core cell of the acoustic sandwich panel.

A honeycomb core includes a honeycomb substrate comprised of a number of sheets. A number of traces are printed onto the sheets of the honeycomb substrate. A number of integrated electronic devices are disposed within the honeycomb substrate. The integrated electronic devices are electrically coupled to the traces.

A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets by creating a resin affinity portion and a resin repellant portion on the sheets. The resin affinity portion and the resin repellant portion forms the venting pathways. A honeycomb substrate is then formed from the sheets.

A method for creating a honeycomb core having venting pathways includes controlling where a resin is applied to sheets to form the venting pathways. A honeycomb substrate is then formed from the sheets.

What is presented is a unit cell comprising a cellular geometry that comprises cell walls and cell edges arranged into a combination of a cubic cell geometry and a tetrahedral cell geometry arranged to have a coincident central vertex. The cubic cell geometry comprises three orthogonal cell faces that intersect at its central vertex. The tetrahedral cell geometry comprises an arrangement of eight tetrahedral cells that share its central vertex such that each tetrahedral cell shares three coincident edges with three other tetrahedral cells in a cubically symmetric arrangement. The tetrahedral cell geometry is combined with the cubic cell geometry such that all vertices of the tetrahedral cell geometry are coincident with the vertices of the cubic cell geometry.

An extrusion die (100) for a honeycomb body, the die (100) including: an input surface (102); an opposing output surface (104); feed holes (108) extending from the input surface (102) toward the output surface (104); discharge slots (106) having a slot width (SW) and a slot length (SL), and extending from the output surface (104) toward the input surface (102); and a plenum (130) fluidly connecting the feed holes (108) and the discharge slots (106). The plenum (130) may include chambers (132) connected to the feed holes (108) and including tapered outlets (134) connected to the discharge slots (106). The plenum (133) may include first chambers (132A) connected to the feed holes (108) and including first tapered outlets (134A), and second chambers (132B) connected to the first outlets and including second tapered outlets (134B) connected to the discharge slots (106).

Nozzles are presented, for application of a setting resin into cells of a honeycomb core to provide the panel with reinforced segments. The nozzle comprises a connector portion and an application head, where the connector portion is adapted to receive setting resin from a resin dispensing device and deliver the setting resin to the application head, and the application head comprises: an exit hole, and a flange surrounding the exit hole. The flange comprises a bottom surface which comprises a planar surface which planar surface has a minimum width around the exit hole. The bottom surface of flange curves upward at its outer perimeter. In some embodiments, the nozzle is optically translucent or transparent. In addition, methods of applying a setting resin into cells of a honeycomb core to form a honeycomb core reinforcement are presented. In some embodiments, the setting resin is a low density void filler.