A composite hat stringer for stiffening a panel includes a plurality of composite fabric plies arranged to form a cap, a pair of flanges and a pair of webs respectively connecting the cap with the pair of flanges. The cap includes at least one 0° composite tape ply interleafed in the composite fabric plies within the cap.

A method for manufacturing a composite barrel structure includes fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The fabricating includes assembling a first layup of composite material and, concurrently, assembling at least one additional layup. The fabricating further includes heating the first layup with the at least one additional layup. A system for fabricating a plurality of panels that are assemblable into partial barrel sections includes a first workstation for fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The first workstation includes a first assembly station configured to concurrently assemble a first layup of composite material and at least one additional layup and a first heating station configured to heat the first layup concurrently with the at least one additional layup to yield the first plurality of composite panels.

A system and method of a modular floor assembly and installation on an aircraft is presented in embodiments herein. A floor assembly comprising an underlayment layer and a decorative layer may be assembled to provide an aircraft floor that meets Federal Aviation Regulations. The floor assembly may comprise structural, adhesive, and magnetic layers creating a floor assembly that may be quickly and easily removable for maintenance and access to compartments below the floor assembly.

An aircraft has a supporting structure and a shell that can be filled with a gas and which is tensioned by the supporting structure. The supporting structure includes a plurality of rod or tube-shaped sections which define a circular, oval or polygonal main clamping plane for the shell.

An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Aircraft stringers having carbon fiber reinforced plastic (CFRP) material reinforced flanges are disclosed. An example stringer to be coupled to a skin of an aircraft comprises a flange. The flange includes a first portion of a first stiffening segment. The flange further includes a first portion of a second stiffening segment coupled to the first portion of the first stiffening segment. The flange further includes a CFRP reinforcement segment coupled to the first portion of the first stiffening segment and to the first portion of the second stiffening segment. The CFRP reinforcement segment strengthens the first portion of the first stiffening segment and the first portion of the second stiffening segment.

There is provided an anti-ballistic aerospace structure, said structure comprising a strike layer defining an outwardly facing surface and an opposing capture layer defining an inwardly facing surface and an intermediate structural layer arranged between the strike layer and capture layer, wherein the intermediate structural layer is spaced relative to the strike layer to define a space between the intermediate structural layer and the strike layer, said space comprising one or more reinforcement elements, and wherein the strike layer is formed of a fiber reinforced plastic laminate comprising at least one metallic layer.

A panel (1000) for a cabin of an aircraft, the panel (1000) including a laminate (150) with a first layer formed of lithiated carbon fibers (100), a second layer form of carbon fibers with a cathode lithium coating (200), and an electrolyte-containing separator (300) interposed between the first and the second layers and a pressure sensor (50a, 50b) on an outer surface of the laminate (150), and a switch (40) to regulate a voltage to the laminate (150) based on an output of the pressure sensor (50a, 50b) so that the panel (1000) expands.

An aircraft structure and its method of construction avoids the inefficiencies involved in current methods of constructing the aircraft structure, reduces the manufacturing time required for constructing the aircraft structure and reduces the cost involved in constructing the aircraft structure. The aircraft structure and its method of construction is comprised of a geodesic or multi-grid framework of intersecting thermoplastic composite strips that are joined to an interior surface of a thermoplastic composite fuselage skin panel through overmolding/co-consolidation of the grid framework and the skin panel.

A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.