Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

A process for manufacturing composite wing covers is provided that includes placing a laminate inside each of a plurality of shaping tools. Shaping the laminates and pressing the laminates against the shaping tools. Retaining the shaped laminates inside the shaping tools and turning over the shaped laminates. Attaching a skin to the shaped laminates and curing the skin and the shaped laminates. Heating the shaping tools and creating a vacuum in the shaping tools.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

According to one implementation, a composite material structure includes a corrugated stringer and a panel. The corrugated stringer has a corrugated structure including portions each having hat-shaped cross section. The corrugated stringer is made of a composite material. The panel is integrated with the corrugated stringer. The is made of a composite material. Further, according to one implementation, a manufacturing method of a composite material structure includes: setting a textile on a laminated body of prepregs; and producing the composite material structure by covering the laminated body with a bagging film, forming a vacuum state in a space covered with the bagging film, impregnating the textile with the resin, and thermal curing of the laminated body of the prepregs. The laminated body is a panel before curing. The textile has a structure corresponding to a corrugated stringer.

This structure is provided with a first composite material 11, a second composite material 12 joined to the first composite material 11 by a film adhesive 21 provided between the first composite material 11 and the second composite material 12, and a corner fillet part 13 provided on a corner part 15 formed by the first composite material 11 and the second composite material 12. The shape of the corner fillet part 13 is a design shape P designed in advance, and the corner fillet part 13 is formed by curing the film adhesive 21 after arranging the film adhesive 21 on the corner part 15 so as to fit into the design shape P.

A method is described. The method is a continuous manufacturing method of an acoustic transmission loss panel resonator core. The acoustic panel is a double-wall panel construction with two sidewall panels and a resonator core. The resonator core is formed from a roll of film. One or more rollers form interconnected resonator chambers in the film. The resonator chambers are in a rectangular lattice shape. The resonator chambers are continuously formed from a single sheet and then bonded to the second sidewall. The resonator core is then attached between first and second sidewalls. The resonator core defines an air gap between the resonator core and the first sidewall.

A setup device for manufacturing a fuselage barrel, made of a fiber composite material, for an aircraft is provided. The setup device for the purpose of reinforcement includes several stringers arranged so as to be spaced apart from each other. The stringers include a base structure to form a load-bearing rigid substructure that is connected to an outwardly curved supporting surface that can be adjusted by means of actuators for the positive setup of the fuselage barrel to be manufactured with the help of form channels for accommodating the stringers. The actuators, designed as pressure-means cylinders, move one or several form channels in radial direction. The form channels are interconnected longitudinally by means of a flexible intermediate element for forming a ring-shaped supporting surface that is closed in a vacuum-tight manner and that overall is able to adjust itself in radial direction.

Method of manufacturing bond panels and bond panel assemblies are provided. In various embodiments, the method may comprise laying up a top skin on a tool comprising a mandrel. The method may further comprise laying out core on the top skin. The method may further comprise laying up back skin to create an assembly. The assembly may comprise the top skin, the core, and the back skin. The method may further comprise placing the assembly in a bag to provide a bagged assembly. The method may also comprise placing the bagged assembly in an autoclave. The method may further comprise subjecting the bagged assembly to a pressure and a temperature for a determined amount of time. In this regard, the back skin, the core, and the top skin may be co-cured in a single autoclave pressurization and heating operation.

An insulation system, having a plurality of materials forming a composition gradient that defines a first coefficient of thermal expansion (CTE) and a second CTE that differs from the first CTE, wherein the plurality of materials include one or more of different metals, plastics, or fibers, and wherein: at a first temperature the insulation system has a first insulation thickness to provide first heat transfer characteristics; and at a second temperature that is less than the first temperature the insulation system has a second insulation thickness that is greater than the first insulation thickness to provide second heat transfer characteristics that are more insulative than the first heat transfer characteristics.