Methods, systems, and apparatuses are disclosed for making co-cured coated composite material comprising composite material prepreg stacks and a coating material, with the coating material comprising an outer layer of thermoplastic film, with the coating material co-cured with the composite material, with the co-cured coating material providing a compressive force on the co-cured coated composite material, components comprising the co-cured coated composite material, and larger structures comprising the co-cured coated composite materials.

A method for manufacturing optical and microwave reflectors includes: placing an assembly comprising a resin-infiltrated tendrillar mat structure on a mandrel; placing a pre-impregnated carbon fiber (CF) lamina on top of the tendrillar mat structure; placing the assembly in a vacuum device so as to squeeze out excess resin; and placing the assembly in a heating device so as to cure the tendrillar mat structure together with the CF lamina, forming the CF laminae into a laminate that combines with the tendrillar mat structure to create a cured assembly. A reflector suitable for one or more of optical and microwave applications includes: a mandrel; a resin-infiltrated tendrillar mat structure placed on the mandrel; and a pre-impregnated carbon fiber (CF) lamina placed on top of the tendrillar mat structure.

Methods of manufacturing a belt include laying up a first elastomeric layer of a belt build on a mandrel, laying up a tensile reinforcement layer on the first elastomeric layer, where the tensile reinforcement layer contains cords coated with a water based urethane compound, and laying up a second elastomeric layer on the first elastomeric layer and the tensile reinforcement layer. The belt build may be cured in a profile-forming mold, and afterward, cut to a predetermined belt width and/or length.

A method for producing a vehicle composite component with a layer structure having a core layer in a molding tool, the core layer being formed with regions of different thickness is provided. Steps for this method may include placing a cover layer, in particular a preformed cover layer, which in particular forms an outer skin of the vehicle composite component, onto a mold base plate of the open molding tool; introducing a first fiber layer, which is impregnated with PU resin and has not been subjected to forming, between the cover layer and a first mold counterplate of the open molding tool; closing the molding tool and compression molding the first fiber layer, which is impregnated with PU resin, against the cover layer, as a result of which a preform with a first support layer containing the first fiber layer is formed and hardened while supplying heat.

A strip of curable prepreg comprising unidirectional fibers aligned with the length of the strip, the fibers being at least partially impregnated with curable thermosetting resin and comprising a flexible polymeric sheet on an outer face of the strip, wherein the strip has a substantially rectangular cross-section defining a width and a thickness of the strip.

The present invention relates especially to an intermediate material comprising, or even constituted exclusively by, an array of individualised ribbons, each ribbon being composed by a tape of unidirectional reinforcing fibres associated, by adhesion, on each of its faces with a veil of thermoplastic fibres, characterised in that the ribbons are disposed in successive layers, in such a way that the ribbons of two successive layers are superposed with or without crossing but without interlacement, the bond between a ribbon and the ribbon or ribbons with which it is superposed being ensured by adhesion, and in that in each layer the ribbons are disposed substantially parallel to each other over at least the major part of their length, while being independent and spaced from each other and in that the ribbons of at least two layers extend in two different directions.

The present invention relates especially to an intermediate material comprising, or even constituted exclusively by, an array of individualised ribbons, each ribbon being composed by a tape of unidirectional reinforcing fibres associated, by adhesion, on each of its faces with a veil of thermoplastic fibres, characterised in that the ribbons are disposed in successive layers, in such a way that the ribbons of two successive layers are superposed with or without crossing but without interlacement, the bond between a ribbon and the ribbon or ribbons with which it is superposed being ensured by adhesion, and in that in each layer the ribbons are disposed substantially parallel to each other over at least the major part of their length, while being independent and spaced from each other and in that the ribbons of at least two layers extend in two different directions.

A fishing rod that includes an elongated, tapered rod blank at least a portion of which is quadrilateral in cross section, the quadrilateral portion of the rod blank diminishing in cross-sectional area toward a tip end of the rod blank, the quadrilateral portion of the rod blank comprising a sandwich-structured composite of a core disposed between facings, the core less dense than the facings, the quadrilateral portion of rod blank less stiff in a casting direction than transverse to the casting direction; fishing line guides mounted at intervals along the length of the rod blank; a reel seat mounted at the base end of the rod blank; and a handle mounted at the base end of the rod blank adjacent to the reel seat.

A method for manufacturing a composite material, a sensor element or an active component of a sensor element. The sensor element is applied in a field device of automation technology. At least two materials with different physical and chemical properties are predetermined depending on a functionality of the sensor element or the active component of the sensor element. An outer shape, into which the at least two materials should be formed, is predetermined. The outer shape is divided into a plurality of virtual spatial regions, wherein in each virtual spatial region the material distribution of the at least two materials occurs homogeneously and periodically according to predetermined rules corresponding to a microstructure. The predetermined rules are ascertained via a computer supported method depending on the predetermined functionality of the sensor element or the active component of the sensor element, wherein digital data, which describe the ascertained distribution of the at least two materials, are transferred to at least one 3D printer. As a printed product the sensor element or the active component of the sensor element is created by the 3D printer based on the digital data.

A structural panel and method of fabricating and manufacturing same comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.