Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.

A fiber reinforced polymer matrix composite structure includes a glass fiber layer and a carbon fiber layer in a cured resin. The glass fiber layer and the carbon fiber layer are laminated and present in a thickness direction of the structure. Two outermost layers of the fiber reinforced polymer matrix composite structure including the glass fiber layer and the carbon fiber layer are both the glass fiber layer. In the structure, a volume fraction of carbon fibers with respect to a total volume of glass fibers and carbon fibers is 0.67 or more.

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.

The invention relates to a cylinder housing (2) for a pressure cylinder (1) of light-weight/hybrid construction, having a support structure (4) comprising an inner tube (6) with ends (7, 8) that are spaced apart in the axial direction, and a first and a second end piece (10, 11) in the region of one of the ends (7, 8) of the inner tube (6). A composite structure (12) made of a fiber-reinforced plastics material is arranged on an outer surface (13) of the inner tube (6). Arranged on an outer surface (16) of the first and the second end piece (10, 11) in each case in a manner distributed over the circumference thereof are a plurality of rod-like winding aids (17) that protrude from the outer surface (16). The winding aids (17) have sufficient strength to allow a winding operation during the application of the threads of the composite structure (12), individual threads of the composite structure (12) being guided during said winding operation around at least one of the winding aids (17) in a deflection region (18) on sides that face away from one another in each case in the axial direction. Following the formation of the composite structure (12), the winding aids (17) are reshaped and at least regionally embedded in the composite structure (12). The invention also relates to a pressure cylinder (1) having such a cylinder housing (2) and to a method for the production thereof.

Filament winding or another technique can be used to create composite parts having various layers of pigmented fibers. The composite parts can then be milled to form one or more flat surfaces on the composite part. Due to the layering of pigmented fibers, the flat surfaces can have a pattern that resembles wood grain or another pattern. These milled composite parts can then be used as components for furniture or other items.

Systems and methods of this disclosure optimize the manufacturing of composite pressure vessels and structures by streamlining the fabrication of tooling and internal structures through use of additive manufacturing processes such as vat polymerization, material or binder jetting, material extrusion, and powder bed fusion to improve quality, scalability, extensibility, and cost effectiveness. In embodiments, a computer readable medium storing computer readable instructions which, when acted upon by a 3D printer, cause the 3D printer to print a mandrel (10) of a composite pressure vessel, the mandrel having a predetermined size, shape, and internal volume (10b) and including at least one end (13) having an opening (17) to the internal volume.