Systems and methods are provided for adjustable tooling. One embodiment is a method that includes laying up a laminate of fiber reinforced material onto a continuous surface that has a convex profile and that comprises a first contoured surface of a fixed mold of a composite layup tool and a second contoured surface of a movable mold of the composite layup tool. The method also includes displacing the movable mold in a direction that is at least partially towards the fixed mold, breaking the continuous surface and releasing the laminate from the composite layup tool.

A mandrel for a molding process that includes a first portion that has a first portion outer surface, a first portion inner surface, a first portion first end, and a first portion second end. A thickness of the first portion first end is greater than the first portion second end. A second portion has a second portion outer surface, a second portion inner surface, a second portion first end, and a second portion second end. A thickness of the second portion first end is smaller than the second portion second end. The first portion inner surface engages the second portion inner surface to form a mandrel that has a constant cross-section.

An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

A method for manufacturing a wing box for aircraft comprises the steps of arranging, on a curing surface, a first panel of composite material, alternately arranging, on the first panel, along a transverse direction, a rib of non-polymerized composite material and a tool comprising a central part, a bottom part and a top part, wherein the central part of each tool is interposed between said bottom part and the top part and may be extracted in a transverse direction, arranging a second panel of composite material by putting said second panel in contact with the flanges of each rib, pulling out the central part of each tool along the transverse direction and removing the top part and the bottom part of each tool, and subjecting the first panel, the second panel, and each rib to a curing process in autoclave with vacuum bag.

An example mandrel for processing a part is described including a plurality of elastomeric components aligned end to end and spaced apart linearly to form a segmented mandrel body, and compressible interconnections positioned within spacing between adjacent elastomeric components and abutting the adjacent elastomeric components. The compressible interconnections allow the plurality of elastomeric components to expand axially due to thermal expansion resulting in a distribution of pressure. An example method for fabricating a composite part is also described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity of the tooling surface such that the base composite layer is between the mandrel and the tooling surface, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing, and removing the mandrel from the cavity of the tooling surface.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

A mold for molding a body or cap for a connector. The mold comprises a mold body (1) and an axial core (2) which together define a mold cavity in the shape of the body or cap. The core has a sleeve (3) and an inner pin (4) each having complementary castellations (8, 10) which interdigitate in a first configuration. In the first configuration, the castellations (8, 10) are arranged such that respective recesses (11) are formed each bound by the proximal end of a first castellation (8) and the side walls of adjacent second castellations (10). Each recess has a shape to form a respective first portion of the body or cap. The sleeve (3) and inner pin (4) are axially movable to a second configuration in which the castellations (8, 10) are disengaged from one another. The inner pin (4) is rotatable to a third configuration in which the first castellations (8) can be axially withdrawn following a path occupied by the second castellations (10) in the first configuration.

A method of producing a cascade array and a cascade array is provided. The method includes: forming a plurality of strongbacks from a first thermoplastic material; forming a plurality of comb subassemblies, each said comb subassembly including one of the plurality of strongbacks and a plurality of vanes comprising a second thermoplastic material extending outwardly from the respective one of the plurality strongbacks; and attaching the plurality of comb subassemblies into a unitary structure to produce the cascade array.