An apparatus for fabricating a composite structure includes a tape placement machine including a delivery head configured to dispose a composite tape and a backing plate coupled to the tape placement machine and selectively located relative to the delivery head to react to a placement force applied by the tape placement machine as the composite tape is being disposed.

A method for manufacturing a semifinished product or component is disclosed in which a metal support embodied as a split strip is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or component by means of roll forming. In order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior to reaching its gel point, the prepreg is formed together with the metal support.

A method for manufacturing a semifinished product or component is disclosed in which a metal support embodied as a split strip is covered with at least one prepreg containing a thermally cross-linkable thermosetting matrix with endless fibers, the thermosetting matrix of the prepreg is pre-cross-linked by means of heating, and the metal support covered with the pre-cross-linked prepreg is formed into a semifinished product or component by means of roll forming. In order to enable plastic deformation in fiber-reinforced regions of the metal support, it is proposed that during the pre-cross-linking of the thermosetting matrix of the prepreg, its matrix is transferred into a viscosity state that is higher than its minimum viscosity and prior to reaching its gel point, the prepreg is formed together with the metal support.

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 of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member. The radius filler element is formed of a permeable material. The method also includes absorbing resin from the composite base member into the permeable material of the radius filler element. The method additionally includes curing or solidifying the resin in the radius filler element and in the composite base member to form a cured composite structure in which the resin bonds the radius filler element to the composite base member.

A method of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member. The radius filler element is formed of a permeable material. The method also includes absorbing resin from the composite base member into the permeable material of the radius filler element. The method additionally includes curing or solidifying the resin in the radius filler element and in the composite base member to form a cured composite structure in which the resin bonds the radius filler element to the composite base member.

An object of the present invention is to provide a stitched fiber-reinforced substrate material capable of suppressing the formation of microcracks in a fiber reinforced composite material. The stitched fiber-reinforced substrate material of the present invention is a stitched fiber-reinforced substrate material formed by stitching reinforcement fiber sheets made of reinforcement fibers using stitching yarns, to which an organic compound having a polar group is adhered. The organic compound having a polar group is preferably a compound having a polyoxyalkylene structure, and also preferably a compound having an epoxy group. The organic compound having a polar group is preferably adhered in an amount of 0.1 to 10 wt % with respect to the mass of the stitching yarn.

A method is provided for preparing a composite product, the method comprising: forming a core structure having a plurality of layers, each layer being build by an additive manufacturing process; wherein the core structure has a shell substantially enclosing an internal chamber of the core structure, wherein the shell is fluid-impermeable, and wherein the outer surface of the shell has a predefined shape; introducing a fluid into the chamber of the core structure; arranging the core structure and reinforcement fibers in a mould, wherein the mould is arranged to accommodate the core structure including the reinforcement fibers, and wherein the reinforcement fibers and the outer surface of the shell are arranged in contact with each other; providing the reinforcement fibers and a resin on the outer surface of the shell of the core structure; and solidifying the resin to form the composite product inside the mould at a moulding pressure P.sub.m, while controlling the fluid pressure P.sub.F of the fluid in the core structure.

A method is provided for preparing a composite product, the method comprising: forming a core structure having a plurality of layers, each layer being build by an additive manufacturing process; wherein the core structure has a shell substantially enclosing an internal chamber of the core structure, wherein the shell is fluid-impermeable, and wherein the outer surface of the shell has a predefined shape; introducing a fluid into the chamber of the core structure; arranging the core structure and reinforcement fibers in a mould, wherein the mould is arranged to accommodate the core structure including the reinforcement fibers, and wherein the reinforcement fibers and the outer surface of the shell are arranged in contact with each other; providing the reinforcement fibers and a resin on the outer surface of the shell of the core structure; and solidifying the resin to form the composite product inside the mould at a moulding pressure P.sub.m, while controlling the fluid pressure P.sub.F of the fluid in the core structure.