A method of manufacturing a radius filler may include providing a plurality of fibers, braiding the plurality of fibers into a braided preform, shaping the braided preform into a braided radius filler, and cutting the braided radius filler to a desired length.

Compaction systems and methods of compacting components are provided. In one aspect, a laminate of a component can be laid up on a tool of a compaction system. The laminate defines a cavity. A noodle is positioned relative to or in the cavity. A noodle ring is then positioned relative to the noodle. For instance, the noodle ring can be placed over the noodle. A cross section of the noodle ring can be shaped complementary to a cross section of the noodle. A plunger of the compaction system is moved so that it engages the noodle ring. Particularly, the plunger is moved in such a way that a force is applied on the noodle ring so that the noodle ring compacts the noodle into the cavity.

A fiber-reinforced composite laminate for use in electromagnetic welding of molded parts of said laminates. The laminate has a plurality of structural layers, each formed of electrically conductive fibers embedded in a thermoplastic matrix. Eddy currents may be induced in the electrically conductive fibers by an electrical conductor that generates an electromagnetic field. The structural layers include a first, a second and, optionally, a third pair of two adjacently positioned structural layers. The first pair has an intermediate layer which allows eddy currents to flow between the two structural layers of the first pair. The second pair has an intermediate layer which prevents eddy currents from flowing between the two structural layers of the second pair. The optional third pair does not have an intermediate layer. The laminate shows efficient heating by an electromagnetic field.

A method for producing a fiber composite laminate, including the steps of applying pressure and/or heat to a first preform, which has one or more dry fiber layers and a thermoplastic elastomer, such that the thermoplastic portion of the thermoplastic elastomer completely impregnates the dry fiber layers of the first preform in at least one first region and only partially impregnates the dry fiber layers in at least one second region and, in a thermosetting polymer matrix, impregnating and curing the fiber layers of the second region of the first preform that are still dry and have not been impregnated with the thermoplastic portion of the thermoplastic elastomer.

An efficient method for manufacturing a partially cured composite component intended to be joined with other component or components to form a composite structure and a manufacturing method of the composite structure. The partial curing of a composite layup is achieved using a mold comprising heat conductive elements and insulating elements and applying heat and pressure over the mold. The heat conductive elements are used to transmit or dissipate heat to/from the composite layup. The insulating elements are used to prevent the transmission or dissipation of heat to/from the composite layup.

A production method for a fiber reinforced composite material includes heating a preform formed by laminating a prepreg layer (I) including a reinforcement fiber (A) and a thermosetting resin (B-1) with a resin layer (II) including a thermosetting resin (B-2) and a solid additive (C) to cure the thermosetting resin (B-1) and the thermosetting resin (B-2), the cured resin layer (II′) formed by curing the resin layer (II) having an average thickness of 35 μm or more and 300 μm or less.

A production method for a fiber reinforced composite material includes heating a preform formed by laminating a prepreg layer (I) including a reinforcement fiber (A) and a thermosetting resin (B-1) with a resin layer (II) including a thermosetting resin (B-2) and a solid additive (C) to cure the thermosetting resin (B-1) and the thermosetting resin (B-2), the cured resin layer (II′) formed by curing the resin layer (II) having an average thickness of 35 μm or more and 300 μm or less.

A method may produce a heat-resistant resin composite excellent in heat resistance and bending properties. This heat-resistant resin composite is constituted of a matrix resin and reinforcing fibers dispersed in the matrix resin. The matrix resin is constituted of a heat-resistant thermoplastic polymer having a glass transition temperature of 100° C. or higher, and a polyester-based polymer comprising a terephthalic acid unit (A) and an isophthalic acid unit (B) at a copolymerization proportion (molar ratio) of (A)/(B)=100/0 to 40/60. The proportion of the heat-resistant thermoplastic polymer in the composite is 30 to 80 wt %.

A method may produce a heat-resistant resin composite excellent in heat resistance and bending properties. This heat-resistant resin composite is constituted of a matrix resin and reinforcing fibers dispersed in the matrix resin. The matrix resin is constituted of a heat-resistant thermoplastic polymer having a glass transition temperature of 100° C. or higher, and a polyester-based polymer comprising a terephthalic acid unit (A) and an isophthalic acid unit (B) at a copolymerization proportion (molar ratio) of (A)/(B)=100/0 to 40/60. The proportion of the heat-resistant thermoplastic polymer in the composite is 30 to 80 wt %.

The present disclosure provides methods and systems for manufacturing a composite component. User input indicative of component parameters for fabrication of the composite component are obtained, the component parameters including a prepreg offcut material parameter indicative of a prepreg offcut to be recycled. At least one staging parameter for a staging process of the prepreg offcut is determined based on the prepreg offcut material parameter. A compression moulding process map for the fabrication is determined based on the component parameters A manufacturing parameters for the fabrication is determined based on the compression moulding process map. At least one signal indicative of the staging parameters, the compression moulding process map, and the manufacturing parameters is issued.