A method for making an electrode assembly comprises overlaying an electrode on an electrode support, the electrode comprising a plurality of openings extending at least partially through a thickness of the electrode; supporting the electrode support with a jaw body; stitching a filament made of electrically insulative material comprising a first inset segment and exposed segment into a first opening of the plurality of openings such that the first inset segment is positioned in the first opening and at least a portion of the exposed segment is positioned to overlie an exposed working surface of the electrode; and affixing at least an end portion of the first inset segment of the filament to the electrode, electrode support, and/or the jaw body.

A method for additively manufacturing a tip structure on a pre-existing part includes: a) placing the part in a build space of a beam-assisted additive manufacturing setup and below a transparent aligning plate, b) engraving a top contour of the part onto the aligning plate with an energy beam of the setup, c) aligning a top surface of the part such that the top surface coincides with the engraved contour, d) removing the aligning plate from the setup, and e) additively manufacturing the tip structure according to a predefined geometry on the top surface.

A method for molding a composite pressure vessel liner to secure a boss to the liner is described. The method comprises providing a moldable liner having an end section with a neck and a port. A boss is positioned around the neck of the liner and the liner is heated and pressure is applied to mold the liner to form to the shape of the boss. The angle of the molded liner secures the boss in place around the liner and it is able to withstand high pressures. A tool for molding the liner and a method for using the tool is also described. The tool comprises a tool body and a pipe having external threads. The tool body abuts the liner and the boss. Winding the pipe exerts pressure on the liner, which when heated, forces the liner to mold to the shape of the boss.

This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

A method for manufacturing a rotor blade root assembly includes placing outer skin layer(s) onto a blade mold and arranging a root plate with a plurality of through holes adjacent to an end face of the blade mold. The method also includes placing a plurality of root inserts atop the outer skin layer(s) and abutting against the root plate, with each of the root inserts defining a fastener hole. The method also includes inserting a root fastener into each of the aligned through holes and longitudinal fastener holes. Moreover, the method includes placing inner skin layer(s) atop the root inserts. Further, the root plate may include at least one fluid hole configured therethrough to provide a non-gas tight root plate. Alternatively, at least one seal may be arranged between the root plate and the blade mold that forms a non-gas tight connection with either or both of the root plate or the blade mold during a vacuum infusion process. Thus, the method includes securing the outer skin layer(s), the root inserts, the inner skin layer(s), and the root fasteners together to form the root assembly via the vacuum infusion process.

A method for manufacturing a rotor blade root assembly includes placing outer skin layer(s) onto a blade mold and arranging a root plate with a plurality of through holes adjacent to an end face of the blade mold. The method also includes placing a plurality of root inserts atop the outer skin layer(s) and abutting against the root plate, with each of the root inserts defining a fastener hole. The method also includes inserting a root fastener into each of the aligned through holes and longitudinal fastener holes. Moreover, the method includes placing inner skin layer(s) atop the root inserts. Further, the root plate may include at least one fluid hole configured therethrough to provide a non-gas tight root plate. Alternatively, at least one seal may be arranged between the root plate and the blade mold that forms a non-gas tight connection with either or both of the root plate or the blade mold during a vacuum infusion process. Thus, the method includes securing the outer skin layer(s), the root inserts, the inner skin layer(s), and the root fasteners together to form the root assembly via the vacuum infusion process.

A method for forming a composite component, comprising: locating a rigid composite element comprising a matrix interspersed with long fibre reinforcement in a mould that is shaped to define a cavity about the rigid element; loading a material comprising a matrix precursor interspersed with short fibre reinforcement into the cavity; and curing the matrix precursor.

A method for forming a composite component, comprising: locating a rigid composite element comprising a matrix interspersed with long fibre reinforcement in a mould that is shaped to define a cavity about the rigid element; loading a material comprising a matrix precursor interspersed with short fibre reinforcement into the cavity; and curing the matrix precursor.

A method for manufacturing a panel for an aircraft is provided. The method includes arranging, on a curing surface, a skin of pre-preg composite material, arranging a plurality of pre-formed, uncured composite stringers, each having an open cross section with a web and a base transverse to each other so that a first base portion protrudes toward a first side and a second base portion protrudes toward a second side, arranging the stringers on the skin with the base in contact with the skin, arranging, on each stringer, a respective first mandrel to completely cover the first base portion and a respective second mandrel to completely cover the second base portion, and having the skin and the stringers undergo a co-curing process in autoclave with vacuum bag.