Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular non-acoustic panels are disclosed.

An extrusion system (100) includes at least one sensor (102, 104) to detect localized presence of oil (701) on an exterior surface (715) or skin of wet extrudate material (714 e.g., ceramic material having a honeycomb cross-sectional shape), and at least one infrared emitting device (106, 108) configured to impinge infrared emissions on at least a portion of the exterior surface responsive to one or more sensor signals. Localized impingement of infrared emissions may reduce presence of oil streaks (701) without undue differential drying of the extrudate skin (715), and avoid surface fissures that would otherwise result in fired ceramic bodies. Separately controllable infrared emitters (502), or at least one controllable infrared blocking or redirecting element (603), may be used to impinge infrared emissions on selected areas. A humidification section (120) arranged downstream of infrared emitters (106, 108) may be used to at least partially rehydrate the wet extrudate material, if necessary.

Spherical heat foamable pellets (2) are used for reinforcing honeycomb structures (4). The pellets are preferably of average diameter from 0.5 mm to 0.9 mm and preferably at least 80% of the pellets have a diameter in this range. The pellets can form a free flowing stream which can be poured into the cells (5) of the honeycomb where they can be foamed by heating to form a reinforcing foam which can also bond the honeycomb structure to facing sheets. It is preferred that the pellets are based on a thermosetting resin and contain a curing agent that can cure the foamed resin to produce an integral rigid reinforcing foam within the cells of the honeycomb.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

A method of producing a cellular structure via an additive manufacturing technique includes the steps of: providing a feedstock material to an additive manufacturing printer device; dispensing the feedstock material from the printer device; and controlling the dispensing of the feedstock material to form at least one layer of the cellular structure according to a first predetermined gradient. In some aspects, the cellular structure comprises an array of cells surrounded, respectively, by walls, and arranged to create a non-uniform relative density and/or cell geometry across a width and/or a height of the cellular structure. An article of manufacture produced by such methods includes a cellular structure configured to produce a controlled collapse with selectable dynamic stiffness characteristics by altering the distribution and geometry of cells within the cellular structure, while being able to maintain a substantially similar static stiffness characteristic.

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 reinforcing structure made of a sheet-like cellular base material which comprises material attenuations (3) in a distribution over its area in a view from above, wherein the material attenuations sub-divide the base material into a multitude of material islands (1R; 1T) which are delineated from each other by the material attenuations (3) but are still connected to each other, wherein (a) the material islands (1R; 1T) are convex base polygons in a view from above; (b) a respective plurality of the material islands (1R; 1T) jointly form a convex and preferably regular compound polygon (1H) in a view from above; and (c) the compound polygons (1H) differ, in their number of corners and/or in a ratio of the lengths of their sides, from the base polygons which form the material islands (1R; 1T).

A method and system for manufacturing a conical shaped acoustic structure. A sheet of acoustical material is cut to form individual pieces using a cutter system. Each individual piece in the individual pieces has a flat pattern for the conical shaped acoustic structure. An individual piece is positioned around a mandrel with a conical shape using an actuator system. Two edges of the individual piece are positioned for joining. The two edges of the individual piece positioned around the mandrel are joined to form the conical shaped acoustic structure.

The present invention relates to a hybrid panel, comprising a panel comprising: a core, a first protecting layer on a first side of said core and a second protecting layer on a second side of said core; said panel defining an outside geometry thereof; and an overmolded portion which overlays at least a part of said panel, thereby changing said geometry of said panel at said part of said panel.

A method is provided for manufacturing during which a first duct section is formed with a tubular first sidewall. A first opening extends through the tubular first sidewall. The forming of the first duct section includes disposing a first woven fiber sleeve over a first mandrel and disposing a polymer material with the first woven fiber sleeve. A second duct section is disposed with a tubular second sidewall. The forming of the second duct section includes disposing a second woven fiber sleeve over a second mandrel and disposing the polymer material with the second woven fiber sleeve. The second duct section is arranged with the first duct section. The second duct section engages the tubular first sidewall. The tubular second sidewall is located at and extends circumferentially around the first opening. A duct structure is formed by attaching the second duct section to the first duct section.