The disclosure discloses apparatus and methods for repairing defects such as porosity and/or edge delamination in composite laminates by infusion of flowable matrix material. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate through the use of a formed hole extending at least partially through the composite laminate. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate in a stepwise manner in order to obtain more complete filling of such space.

A system and method for forming 3D printed structures includes printing an outer shell portion and filling an interior of the outer shell portion to form an inner portion. The outer shell portion and inner portion may have differing material properties. The outer shell portion may be anchored to the base component.

Some embodiments may include a closure element for a vacuum valve that may be configured, for example, for the gastight closing of a process volume by means of cooperation with a vacuum valve opening of the vacuum valve. In some embodiments, the closure element may include a first sealing surface, corresponding to a second sealing surface of the vacuum valve opening, wherein the second sealing surface surrounds the vacuum valve opening, and a sealing material vulcanized onto the first sealing surface and in accordance with its course and having a defined height in the direction of the surface normal of the first sealing surface. In some embodiments, the sealing material may have a defined shape with respect to a sealing material cross section, comprising a first seal portion, provided on the process volume side, and a second seal portion, provided, in particular, facing away from the process volume.

An apparatus and methods include infusing the flowable matrix material into a space in the composite laminate through the use of a formed hole extending at least partially through the composite laminate. In addition, the apparatus and methods include infusing the flowable matrix material into a space in the composite laminate in a stepwise manner in order to obtain more complete filling of such space.

Apparatus and methods for injecting molten filler material into a hole. The method in accordance with one embodiment comprises: drilling a hole in a composite layer; heating filler material comprising an electrically conductive low-melting alloy to a molten state; inserting a nozzle having an internal channel system into the hole with a gap separating the nozzle and the hole; forcing molten filler material into, through and out of the internal channel system of the nozzle and into the gap; and retracting the nozzle from the hole. The nozzle may be rotary or not rotary.

A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

A manufacturing method of a composite structure includes: (a) preparing: a metallic sheet(s) having a through-hole(s) penetrating throughout the metallic sheet(s) in its thickness direction; (b) setting a prepreg(s), constituting a fiber reinforced plastic sheet(s), and the metallic sheet in a pair of dies, which have a recess(es) arranged at a position(s) opposed to one side opening(s) of the through-hole(s), the recess(es) having a larger diameter than the one side opening; (c) closing the dies, wherein, upon closing, (ca) the prepreg(s) and the metallic sheet are molded to the predetermined shape, while surface-contacting therebetween, (cb) at least one of the prepreg(s) and a patch member(s) is extruded into the through-hole(s), so that the shaft part is molded, and (cc) the patch member(s) forms at least part of a head part(s) in the recess(es), the head part(s) integrated with the shaft part(s) and engaging on the metallic sheet(s).

The present invention recites a method of fabricating a stator for a downhole motor, the method comprising the steps of providing a stator tube having an interior surface and applying a bonding agent to the interior surface of the stator tube. Additionally, a mandrel is positioned within the stator tube, the mandrel having an outer geometry that is complimentary to a desired inner geometry for the stator. Furthermore, a reinforcing material is introduced into the stator tube to fill space between the mandrel and the interior surface of the stator tube and subsequently solidified to bond the reinforcing material to the interior surface of the stator tube. The mandrel is then removed from the bonded stator tube and reinforcing material such that a stator is fabricated.

A system and method for forming a composite filler. The method comprises applying a pressure to a first portion of a composite material blank with a pair of forming dies of a composite filler forming apparatus, the pair of forming dies having a pair of convex radii, each forming die of the pair of forming dies having a respective convex radius of the pair of convex radii. The method also repeats the applying step to a subsequent portion of the composite material blank to incrementally form the composite material blank into a desired cross-section along its length.

A system for repairing a component made out of a plastic comprises a frame, a multiaxial guide device coupled with the frame, with a tool holder arranged thereon, an optical acquisition device, a processing device, and a plastic deposition device. The frame comprises a mounting device for retaining the frame on a component surface. The optical acquisition device, the processing device and the plastic deposition device are arranged on the tool holder. The optical acquisition device is set up to optically inspect a surface area of the component lying in proximity to the frame from at least one viewing angle, so as to acquire the spatial structure of the surface area. The processing device is set up to remove material of a damaged area from the component for generating a base surface with a desired structure and boundary edges.