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.

Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

A system for forming multiple braided preform segments includes a mandrel assembly disposed along a mandrel axis, a radial braider for winding fibers onto the mandrel assembly to form a continuous braided article, an applicator for applying a polymer binder to the braided article while mounted on the mandrel assembly, and a debulking tool for debulking the braided article while mounted on the mandrel assembly. The mandrel assembly includes a lead-in extension defining a first end, an end extension defining a second end, and a plurality of mandrels removably connected to a plurality of transition pieces and disposed axially between the lead-in extension and the end extension.

A method for forming composite components includes disposing composite laminate over a mandrel. The method further includes infusing the composite laminate with a resin. A gelation of the infused resin is caused by applying a first environmental condition to the composite laminate and mandrel. At least a portion of the mandrel is deformed by applying a second environmental condition to the composite laminate and mandrel. The method further includes forming a composite structure by curing the composite laminate infused with resin. The deformed mandrel is removed from the composite structure after forming the composite structure.

A method of fabricating a ceramic matrix composite component includes fabricating a ceramic preform, the preform comprising a hollow portion with an internal cavity extending along a first axis from a first end to a second end of the hollow portion, supporting the hollow portion with an auxetic mandrel disposed within and the internal cavity and coaxial with the hollow portion, the auxetic mandrel comprising a first mandrel end and a second mandrel end, at least partially densifying the preform with a matrix, and removing the auxetic mandrel from the internal cavity by simultaneously applying a compressive force to each of the first mandrel end and the second mandrel end creating a deformed auxetic mandrel to reduce a cross-sectional profile of the auxetic mandrel along a second axis orthogonal to the first axis, and extracting the deformed auxetic mandrel from the first end of the hollow portion.

A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.

A method of fabricating a ceramic matrix composite component includes fabricating a ceramic preform, the preform comprising a hollow portion with an internal cavity extending along a first axis from a first end to a second end of the hollow portion, supporting the hollow portion with an auxetic mandrel disposed within and the internal cavity and coaxial with the hollow portion, the auxetic mandrel comprising a first mandrel end and a second mandrel end, at least partially densifying the preform with a matrix, and removing the auxetic mandrel from the internal cavity by simultaneously applying a compressive force to each of the first mandrel end and the second mandrel end creating a deformed auxetic mandrel to reduce a cross-sectional profile of the auxetic mandrel along a second axis orthogonal to the first axis, and extracting the deformed auxetic mandrel from the first end of the hollow portion.