The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

Systems and methods for pressing a door assembly involve one or more die sections installed in a press, wherein the die sections each have a raised section that contacts and supports a recessed panel portion of a door skin of the assembly during the pressing operation to facilitate crushing of portions of a core of the door assembly that underlie the recessed panel portion of the door skin. The die sections may be made of plastic and readily changed out for different sizes or styles of doors.

A composite case for a gas turbine engine includes an inner structure assembly defining an impact containment zone. The inner structure assembly is configured to circumscribe a plurality of rotatable blades of the gas turbine engine and to receive blade fragments in an event of blade failure. The inner structure assembly includes one or more layers containing a resin impregnated therein, and an outer structure assembly surrounding the inner structure assembly and integrally molded thereon. The outer structure assembly includes one or more layers containing a resin impregnated therein. One or more layers of the inner and the outer structure assemblies include resin reinforced by nanoparticles.

A heated floor panel assembly for aircraft includes an impact layer made from a 2-D or 3-D woven high temperature thermoplastic fiber matrix impregnated with a resin. The impact layer can further include woven metallic fibers. The assembly also includes a stack of structural layers, a heating layer, and a core layer for absorbing shear stress.

Modular armor for a hard upper torso (HUT) of an atmospheric suit that maintains a specific atmosphere within the suit includes a first outer layer including a first surface and a second surface opposite the first surface and a second outer layer including a first surface and a second surface opposite the first surface. A core is sandwiched between the first surface of the first outer layer and the first surface of the second outer layer. The armor is fabricated such that the second surface of the first outer layer is conformally affixed to the HUT.

An acoustic liner is provided. The acoustic liner includes a face sheet, a back sheet spaced from the face sheet, and a core layer defining a cellular structure disposed between the face sheet and the back sheet. The core layer includes a plurality of first resonant cells coupled to the back sheet. Each of the first resonant cells includes a first cell wall coupled to the back sheet along a first cell wall base edge, the first cell wall extending from the back sheet toward the face sheet, the first cell wall further coupled to the face sheet along a first cell wall top edge, wherein the first cell wall of each of the first resonant cells comprises a surface extension that extends from a surface of the first cell wall.

A low-density, halogen-free epoxy composition that is flame-resistant upon curing and is suitable for use as a potting compound. The epoxy composition includes: (a) an epoxy component; (b) at least one curative; (c) at least one latent curing accelerator; (d) a toughening component that includes nano-sized core shell rubber (CSR) particles having particle size of less than 1 micron; (e) a fire-retardant component that is halogen-free; and (f) hollow microspheres for reducing the density of the composition. The fire-retardant component includes a mixture of: (i) at least one polyphosphate; (ii) at least one metal borate; and (iii) at least one compound selected from alkaline earth metal hydroxides and aluminum hydroxides.

An acoustic panel (for absorbing sound) includes a first sheet with spaced microperforations, a second sheet with microperforations more widely spaced than the microperforations of the first sheet, and a first cellular core sandwiched between the first sheet and the second sheet. The panel can be spaced from a surface, such as a wall. A second cellular core can be provided between the second sheet and a third sheet. The third sheet is preferably solid without microperforations but can have microperforations. Noise Reduction Coefficient (NRC) can be 0.8.

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.

Adhesive bondlines in a cell-based structural array are thermally cured using tooling blocks inserted into the cells. The tooling blocks have embedded susceptors that are inductively heated by an alternating electromagnetic field generated by an electromagnet.