Embodiments of the invention provide body armor composite and methods of fabrication. The body armor composite can include at least one strike-face layer, at least one strike-face reinforcement layer, and at least one catchment layer. Some embodiments include body armor composite with a bump guard layer, and a back-face reduction layer. In some embodiments, the fabrication method includes bonding multiple layers to form an armor composite. Some embodiments include an armor production tool including a housing at least two housing portions which form a substantially air-tight chamber when closed. The tool can include a lower flexible membrane forming at least a portion of a mold, and an upper flexible membrane capable of engaging the lower flexible membrane. The tool can include a pressure port for pressurizing the chamber and to move portions of the mold towards each other, and a locking mechanism for locking the two housing portions.

A fiber-reinforced resin member is provided in which a non-conductive sleeve and first and second non-conductive sheets are disposed between a metal fastening member and CFRP laminate, electrical continuity between the metal fastening member and the CFRP laminate is cut off, and corrosion of the metal fastening member due to galvanic corrosion is prevented. A first annular space is formed between a first flange portion of a first member and the first non-conductive sheet, a second annular space is formed between a second flange portion of a second member and the second non-conductive sheet. Therefore, even if frayed carbon fiber sticks out from a gap between the non-conductive sleeve and the first and second non-conductive sheets, due to the first and second annular spaces being formed therein, it is possible to prevent the sticking-out carbon fiber from contacting the first and second members and providing electrical continuity.

A fiber composite laying device for producing a fiber composite scrim for forming a fiber composite component has a laying head which is designed or configured to continuously supply a reinforcement fiber band, a compaction roller which is designed or configured to receive the supplied reinforcement fiber band, lay the band on a laying surface and press the band onto the laying surface at an average compaction pressure, and pressure sensors which are arranged on the compaction roller and are designed or configured to detect a local compaction pressure on the laid reinforcement fiber band.

An in-situ melt processing method for forming a fiber thermoplastic resin composite overwrapped workpiece, such as a composite overwrapped pressure vessel. Carbon fiber, or other types of fiber, are combined with a thermoplastic resin system. The selected fiber tow and the resin are prepared for impregnation of the two by the resin. The resin is melted and the carbon fiber is impregnated with the melted resin under pressure at the filament winding machine delivery head, under pressure and the molten composite is maintained and is applied to the heated surface of a workpiece. The surface of the workpiece is heated to the melting point of the thermoplastic resin so that the molten composite more efficiently adheres to the heated surface of the workpiece and so that the layers of composite remain molten resulting in better adherence of the layers to one another.

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.

The disclosure is directed to a method of manufacturing a layered component. The method includes changing a working pressure in a bladder having a shape and containing a fluid and a plurality of jamming media to convert the bladder into a rigid state. The working pressure is different than an ambient pressure. One or more layers of precursor material are laid on the bladder while the bladder is in the rigid state. The one or more layers of precursor material are processed to form the layered component. The working pressure in the bladder is returned to the ambient pressure to return the bladder to a flaccid state. The bladder, while in the flaccid state, is removed from the layered component.

Systems and methods are provided for utilizing pellet-loaded bladders to consolidate and/or harden composite parts. One embodiment is a method for fabricating a composite part. The method includes laying up a preform that is made of fiber reinforced material and that includes a cavity, inserting one or more bladders that are loaded with expandable pellets into the cavity, inflating the bladders in response to a triggering condition, consolidating the preform while the bladders are inflated, deflating the bladders, and removing the bladders from the cavity.

Provided are a carbon fibre thermoplastic resin prepreg which is a carbon fibre prepreg obtained by impregnating a PAN-based carbon fibre in which the average fibre fineness of a single fibre is 1.0 dtex to 2.4 dtex with a thermoplastic resin, wherein the thermoplastic resin satisfies 20<(FM/FS)<40 (where FM: flexural modulus (MPa) of a resin sheet comprising only the thermoplastic resin, and FS: flexural strength (MPa) of the resin sheet), a method for manufacturing the same, and a carbon fibre composite material employing the carbon fibre prepreg.

In one aspect, there is an engagement member for splicing a spar assembly in an aircraft wing including a joining portion having a first attachment for connecting to a first spar and a second attachment surface for connecting to a second spar; and a rib post extending from the joining portion and disposed between the first attachment surface and the second attachment surface. In an embodiment, the rib post is integral to the joining portion and is configured to couple with a rib web.

There is provided a method of manufacturing a composite structure of an aircraft. The composite structure includes a skin and a reinforcing material. The method includes, by stacking unhardened composite sheets on a region of a jig adjacent to a holding portion to hold the reinforcing material, forming a skin inner layer including a retainer to retain two end portions of a flange of the reinforcing material in a width direction of the flange. The method includes installing the reinforcing material at the holding portion of the jig so that the two end portions abut upon the retainer. The method includes, by stacking unhardened composite sheets on an outer surface of the flange and on an outer surface of the skin inner layer, forming a skin outer layer. The method includes hardening the skin inner layer and the skin outer layer.