A method and apparatus for forming a composite structure. A plurality of consolidated overbraided thermoplastic preforms are co-consolidated in a circumferential stackup that is circumferentially constrained. Fibers of the plurality of consolidated overbraided thermoplastic preforms are tensioned during co-consolidation.

A method and apparatus for forming a composite structure. A stackup comprising a plurality of overbraided thermoplastic members and an overbraided thermoplastic skin is built. The stackup is placed between an inner tooling and an outer tooling. The inner tooling, the stackup, and the outer tooling are held in place together using a load constraint. The inner tooling, the stackup, the outer tooling, and the load constraint form a consolidation setup. The consolidation setup is heated to form the composite structure.

Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

A method for determining pane thicknesses and a wedge angle of a coated windshield for a projection arrangement of a head-up display. A wedge angle and a combination of glass thicknesses are determined by means of which the glass ghost image and the layer ghost image are optimally reduced. The method proceeds from a starting thickness of the two glass panes of the windshield for which that wedge angle is determined, in an iterative process, that represents an optimal compromise between the minimization of the glass ghost image and the minimization of the layer ghost image. Then, the glass thicknesses are determined varied within a specified range for each combination of the optimal wedge angles. Thus, it is possible, iteratively, to identify that combination of glass thicknesses that results in the least occurrence of ghost images, in addition to the associated optimal wedge angle.

Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a flange forming device at the ply of material on the forming tool, the flange forming device including an inflatable contact element pressurized to define a deformable contact surface, applying, by the deformable contact surface, the ply of material onto the forming tool with a predetermined pressure, wherein the deformable contact surface is moved across the forming tool, and wherein the inflatable contact element is configured to maintain the predetermined pressure as the deformable contact surface transitions from the web surface to the at least one flange surface.

A method of manufacturing a medical component includes preparing a first sheet of an elastomeric material, arranging at least one electronic device in the first sheet of elastomeric material to obtain an elastomeric preform, and arranging the elastomeric preform in a mold and molding the elastomeric preform therein to cure the elastomeric material and form the medical component having the at least one electronic device embedded therein.

An apparatus and method are provided for forming a pouch case with improved forming quality and minimized surface contact between the forming apparatus and the pouch case in the forming process to form a pouch cup. The apparatus includes a mold on which a pouch case with a plate shape can be placed, wherein the mold bulges upwards, a chamber open at bottom to the pouch case and the mold, the chamber having an inner space in which the mold can be received by lift-up of the mold or lift-down of the chamber, wherein the chamber is seated on an edge portion of the pouch case, and the chamber is equipped with a fluid input valve at top and a fluid output valve at bottom, and a fluid supply unit configured to supply a fluid via the fluid input valve to carry out pressure forming of the pouch case.