A method of determining a void volume during manufacture of a composite pipe formed of concentric layers of adjacently positioned, helical windings of composite tape has the steps of: (a) scanning the surface of a layer of adjacently positioned, helical windings to generate scanning information; (b) using the scanning information to locate gap(s) between adjacent windings and to determine the number of gaps and characteristic dimensions of each gap in the layer; and (c) generating a calculated void volume of the layer, using the number of gaps and the characteristic dimensions of each gap for the layer. The invention also relates to a corresponding apparatus for determining a void volume during manufacture of a composite pipe formed of concentric layers of helically wound composite tape.

A fiber-reinforced resin composite configured to be to be used for a vehicle body structure has a cylindrical shape and a longitudinal direction. The fiber-reinforced resin composite includes first fibers and second fibers. The first fibers are disposed along an axial direction of the cylindrical shape. The second fibers are wound over an entire circumferential surface along a direction intersecting the axial direction of the cylindrical shape. The number of the first fibers per unit area in a tensile surface that is to mainly receive tensile stress upon a collision of a vehicle body is larger than the number of the first fibers per unit area in a compressive surface that is to mainly receive compressive stress upon the collision of the vehicle body.

A high-pressure tank fabrication method includes a pre-form fabrication step and a molding step. In the pre-form fabrication step a pre-form is fabricated by winding dry fiber bundles with different thicknesses (first fiber bundles and second fiber bundles) onto a liner in a state in which the dry fiber bundles with different thicknesses are made to be adjacent to one another. In the molding step, molding includes disposing the pre-form fabricated in the pre-form fabrication step in a mold and injecting resin.

A hybrid metallic/composite structural component may comprise a metallic inner tube, a first lobe extending from the metallic inner tube, and a composite outer tube surrounding the metallic inner tube and the lobe, wherein a first end of the metallic inner tube extends from the composite outer tube and a second end of the metallic inner tube extends from the composite outer tube.

A method of manufacturing a wrapped object, having a first segment and a second segment connected to each other by a curved transition segment having a common tangent with the first segment and a common tangent with the second segment, respectively. The method includes providing a mandrel with a surface structure to define at least part of the shape of the first segment, of the shape of the second segment and of the shape of the transition segment in between, and wrapping, one or more elongate elements over the mandrel and bonding the elongate element(s) to itself and/or each other so as to provide the first segment, the second segment and the transition segment as a continuous structure. The mandrel is provided with a fortification to support the element(s) forming the transition segment against inward-directed forces while wrapping and/or bonding the element(s) to form the transition segment.

A manufacturing method for a high-pressure tank is a manufacturing method for a high-pressure tank including a reinforced layer formed such that an electrically conductive fiber bundle impregnated with thermosetting resin is wound around a liner. The manufacturing method includes: a step of preparing the tank in which the uncured reinforced layer is formed on the liner; a first heating step of heating the uncured reinforced layer by low-frequency induction heating so the thermosetting resin is softened; and a second heating step of, after the first heating step, heating the softened reinforced layer by high-frequency induction heating so that the softened reinforced layer is hardened.

A cascade for a jet engine thrust reverser is fabricated by co-consolidating pre-consolidated thermoplastic strongbacks and vanes. The strongbacks are reinforced with continuous fibers, and the vanes are reinforced with discontinuous fibers.

A method, apparatus, and system for winding a filament around a substrate includes mounting the substrate to a rotatable structure and rotating the substrate to wind the first filament around the substrate in a first winding orientation that winds the first filament around a first pair of edges of the substrate to wrap a first filament layer around the substrate. The method further includes changing winding orientations of the first filament from the first winding orientation to a second winding orientation by turning the first filament about a corner of the substrate and winding the first filament around the rotating substrate in the second winding orientation that winds the first filament around a second pair of edges of the substrate, wherein the second pair of edges is different from the first pair of edges, to wrap a second filament layer around the substrate.

A mandrel structure for use in manufacturing a fiber reinforced resin vessel by a filament winding process, includes: a shaft having a pair of axial ends configured to be supported by a drive unit; a mandrel having the shaft passed therethrough; and a pair of fittings having the shaft passed therethrough and projecting axially from respective axial ends of the mandrel. The mandrel is formed as a hollow shell made of a water-soluble material, and includes a pair of shaft holes receiving the shaft therein, and a receiving recess formed in a part of the mandrel surrounding each shaft hole and configured to engage the corresponding fitting in a rotationally fast manner.

A mandrel for manufacturing a fiber reinforced resin vessel by a filament winding process includes: a tubular part; and a pair of end parts joined to respective axial ends of the tubular part. The tubular part and the end parts are each made of a molded product of a material including pulp and a starch-based binder.