A method of fabricating a composite structure is presented. The method comprises laying up a plurality of composite plies over a layup mandrel; positioning a first caul plate and a second caul plate over the plurality of composite plies, leaving composite material exposed; removing at least part of the composite material exposed between the first caul plate and the second caul plate to separate a first composite section from a second composite section; curing the first composite section and the second composite section to form a first composite part and a second composite part; and removing the first composite part and the second composite part from the layup mandrel immediately following curing.

Systems and methods are provided for a caul plate having a feature for removal. One embodiment is a caul plate for forming a composite part. The caul plate includes a body that includes a lower surface which faces the composite part, and an upper surface that is opposite to the lower surface. The caul plate also includes a groove in the upper surface to accept a tool to slide the caul plate laterally from the composite part.

A caul plate for application onto an uncured composite material which includes a first slit defined by and which extends through and along the caul plate. Further included is a method for curing a composite material part having geometric change within the part. The method includes fabricating a part constructed from uncured composite material having a geometric change within the uncured composite material, which includes a step of positioning a caul plate in overlying relationship to the uncured composite material having a geometric change in the uncured composite material, wherein the caul plate includes a first slit defined by and which extends through and along the caul plate.

A caul plate assembly for applying compaction pressure to a composite structure includes caul plates arranged side-by-side on the surface of the composite structure. The caul plates include overlapping edges of compliant material which form a continuous face applying even pressure and shear across gaps between the caul plates.

Systems and methods are provided for facilitating pick and placement of preforms. One embodiment is a method for picking and placing a preform. The method includes placing an inner surface of a first caul plate into contact with a first side of a stringer preform, such that an outer surface of the first caul plate forms a first plane that is uniform along a length of the stringer preform, placing an inner surface of a second caul plate into contact with a second side of the stringer preform, such that an outer surface of the second caul plate forms a second plane that is parallel to the first plane along a length of the stringer preform, grasping the caul plates at the first plane and the second plane along the length of the stringer preform, and lifting the stringer preform together with the caul plates while maintaining the grasp.

Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting an end caul comprising a structure of sintered material surrounding volumes of unsintered particles, creating a laminate comprising fibers within a resin matrix, placing the end caul in contact with an end of the laminate, and processing the laminate.

Aspects of this disclosure relate to apparatuses and methods that employ a press pad for forming shoe parts, or subassemblies, for example a sole subassembly. The adaptive pad may conform to a topography of a pattern of recesses of a shoe part and provide sufficient rigidity to facilitate formation of a bond during pressing of the one or more shoe parts to form the sole subassembly.

A method for molding fiber-reinforced plastic. A core is formed in a desired shape by accommodating, in a flexible bag, a grain group containing plurality of grains. The core is placed inside a prepreg containing resin and fibers, and the prepreg, in which the core is housed is placed in a molding die and compression molded. When doing so, the grain group contains first and second grains (a,b) that satisfy the equation (1). (1) 1.1(Da/Db)2.0 In the equation Da is the grain diameter of the grains (a), and Db is the grain diameter of the grain (b). When using a molding die to mold a molded article having a cavity, the above mentioned molding method enables an increase in the internal pressure of the core in order to change the peripheral surface area of the core, without using a pressurized gas and/or pressurized liquid.

Cauls and methods of using cauls to produce composite articles are provided. The caul transitions from a rigid state to an elastomeric state and from an elastomeric state to a rigid state in response to a stimulus and has a reinforcement density of from 100 kg/m.sup.3 to 500 kg/m.sup.3. Methods of using cauls to produce composite articles involve positioning one or more fiber layers between a caul and a cure mold surface when the caul is in a rigid state. The fiber layers, caul, and cure mold surface may be covered with a sealed barrier and a pressure gradient may be applied. Before, after, or before and after performing the vacuum the fiber layers may be impregnated with resin. The fiber layers may be cured, which may provide a stimulus to transition the caul from a rigid to an elastomeric state, and the composite article is produced.

A flexible-die forming apparatus includes a piston, a coil, an upper die, a magnetorheological elastomer, and a lower die having a cavity formed thereon. The upper die is arranged to be overlappedly rested on top of the lower die. The piston is movably received in the receiving cavity of the upper die. The magnetorheological elastomer is mounted at a lower portion of the piston, and is received in the receiving cavity of the upper die. The coil is provided and wounded on an exterior surface of the upper die and the lower die.