Systems and methods are provided for fabricating composite parts. One embodiment is a method of fabricating a composite part. The method includes providing a preform on a tool mandrel, positioning sensors around the preform according to a target shape of the composite part, and sealing the preform with a vacuum bag to form a chamber. The method also includes applying temperature and pressure to the chamber to infuse a resin into the preform to create a composite preform undergoing infusion, monitoring a thickness of the composite preform prior to completing cure, and adjusting at least one of the temperature and the pressure prior to completing cure based on the thickness.

A drape forming apparatus includes a forming tool having a first forming surface and a second forming surface nonplanar with the first forming surface. A tray is spaced apart from the forming tool and is configured to pivot about a hinged end from a first position to a second position under an applied force such that a distal end moves away from the forming tool. A first side of the tray faces a first heat source when the tray is in the first position, and a second heat source is disposed at a second side of the tray. A device for use in forming the composite structure includes a standoff and the tray, and a heat source is secured to the second side of the tray. A method of forming a composite structure includes heating both sides of the composite material with the first and second heat sources.

An intensifier mechanism for forming stacked material includes a support, a first body coupled to the support, and a second body having a main portion, a pivoting portion, and a joint. The main portion is coupled to the support and the joint movably couples the main portion to the pivoting portion. The joint allows the pivoting portion to pivot in relation to the main portion when the membrane moves towards the bottom wall.

A method for molding a composite material includes arranging a prepreg on a jig molding surface of a jig for molding. The method includes sealing a first endless seal region that surrounds the prepreg is formed by bonding a resin bag and the jig molding surface by a first sealing material and a second endless seal region that surrounds the prepreg and is positioned outside the first seal region is formed by bonding a resin bag and the jig molding surface by a second sealing material. The method includes depressurizing a first space inside the first seal region and a second space between the first seal region and the second seal region are depressurized. The method includes thermally curing the prepreg by supplying a water vapor into the internal space of a pressure vessel, while holding the pressure vessel in a sealed state.

Manufacturing structure using a composite material includes: a tapering step for forming a first tapered surface on a first stiffener in an uncured state; a bending step for bending the stiffener such that a second surface is on the inner side; an arranging step for arranging the first stiffener and a skin at prescribed positions; a vacuum suctioning step for vacuum suctioning the first stiffener and the skin; and a bonding step for curing the first stiffener to bond the first stiffener and the skin. In the tapering step, the angle formed between the first tapered surface and the second surface is an acute angle. In the vacuum suctioning step, the first tapered surface is brought into contact with the skin while maintaining contact between the first surface and the skin, and the first stiffener is deformed so that a second tapered surface is formed on the second surface.

One embodiment of a method according to the present disclosure may use a fixture with one or more boot recesses formed therein. An embedded member may be engaged with a boot and placed in a boot recess. Substrate lay-up may be placed around all or a portion of the embedded member and an outer member may be positioned over the substrate lay-up. A cover may be positioned over the outer member and engaged with the fixture. The pressure within an interior portion of the fixture may be reduced to less than ambient pressure and resin may be introduced to interact with the substrate lay-up and allowed to cure.

The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.

The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.

A bladder bag is a mold for molding inside of a composite material structure. The composite material structure includes a narrow portion formed by narrowing a part of the inside and a space portion formed so as to be adjacent to the narrow portion. The bladder bag includes a bladder bag main body and a cord-like member. The bladder bag main body includes a narrow molding portion for molding the narrow portion of the composite material structure, a space molding portion for molding the space portion of the composite material structure, and an air intake for introducing air. The cord-like member is provided inside the bladder bag main body, passes through the narrow molding portion from the air intake, and is connected to an inner surface of the space molding portion.

Manufacturing structure using a composite material includes: a tapering step for forming a first tapered surface on a first stiffener in an uncured state; a bending step for bending the stiffener such that a second surface is on the inner side; an arranging step for arranging the first stiffener and a skin at prescribed positions; a vacuum suctioning step for vacuum suctioning the first stiffener and the skin; and a bonding step for curing the first stiffener to bond the first stiffener and the skin. In the tapering step, the angle formed between the first tapered surface and the second surface is an acute angle. In the vacuum suctioning step, the first tapered surface is brought into contact with the skin while maintaining contact between the first surface and the skin, and the first stiffener is deformed so that a second tapered surface is formed on the second surface.