The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

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 honeycomb structural body includes multiple cores, at least face sheet, and at least one reinforcement sheet. The multiple cores each have a honeycomb structure, and are bonded to each other with foamed adhesive in a direction in which the number of multiple pores formed by the honeycomb structure increases. The at least one face sheet is adhered to the multiple cores so as to cover the multiple pores. The reinforcement sheet is placed between the multiple cores and the at least one face sheet, at a position where the reinforcement sheet covers the foamed adhesive.

A method of fabricating an artifact (15) includes treating natural fibers (110) with a non-halogenated flame retardant agent (120), the fibers (110) also being treated with a smoke suppressant (120). At least one pre-preg is formed (170, 180) from the treated natural fibers and from a resin composition (160) including a smoke suppressant (150) admixed therein (160). An uncured artifact is formed from a core or substrate (12) and the pre-preg, which provides a skin, and is cured (210). A non-fibrous silicate fire resistant material (190, 230) is introduced by: (i) admixing the fire resistant material with the resin composition, and/or (ii) applying the fire resistant material to an outer surface of the pre-preg or an outer surface of the skin of the uncured artifact, and/or (iii) applying the fire resistant material to an outer surface of the skin of the cured artifact. The invention extends to a flame-proofed artifact (15).

A structural panel for an aircraft nacelle may comprise a first skin, a second skin, and a core sandwiched between them. One of the skins may comprise regions of different thicknesses. The regions of different thicknesses may be separated by a ramp, in which the number of composite plies in the first skin varies. A slope of the ramp may vary across the ramp to prevent disbonding of the core from the skin at the base of the ramp.

A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, an assembly to apply bonding pressure to the plies at least at the core and trim areas and a clamping device external to the assembly to apply a clamping force to the vacuum bag and the plies.

An energy efficient film comprising of first and second substrate layers and microstructures positioned between the first and second substrates is provided. The microstructures are positioned between the first and second structures such that a vacuum environment is created between the first and second substrates. In one embodiment, the insulating film includes a first substrate, a second substrate, and a plurality of microstructures positioned between the first substrate and the second substrate, such that a vacuum environment is created between the first and second substrates and within each microstructure cell, individually. Preferably, the plurality of microstructures is a polygonal cellular network positioned between a first transparent substrate and a second transparent substrate. A gasket may be provided on one or both of the first or second substrates. The gasket may also be provided on outer edges of the first and/or the second substrate.

Embodiments disclosed herein relate to polymer resins having a first thermoset and one or more additional components (e.g., a second thermoset and/or a thermoplastic), composite laminates including the same, methods of making and using the same, and composite laminate structures including the same.

For forming a sound absorption/insulation honeycomb panel by stacking an air-permeable material, a honeycomb material filled with a sound absorption material and a reflector, and adhesively joining these materials, it is hard to join the honeycomb material and the air-permeable material adhesively due to a thin wall surface of the honeycomb material and a resultant line to surface adhesive joint therebetween, causing a problem of low adhesive strength. By using a water absorption honeycomb material, an adhesive joint is formed with an adhesive joint area increased by dipping an end of a wall surface of a cell forming the water absorption honeycomb material into a water-soluble adhesive, making the end flexible over a fixed period of time, and then pressing the end strongly against an air-permeable material as a counterpart of the adhesive joint to deform a tip into an inverted T-shape.

The present disclosure relates to a method of repairing a damaged portion of a perforated skin of a panel using a doubler made of composite material which is designed to be applied to the damaged portion of the perforated skin. The method includes at least one step in which a sealing film is applied to the damaged portion of the perforated skin in order to temporarily seal the perforations in the skin, and a step in which the doubler is produced over the previously deposited sealing film.