A radome structure for a multilayered broadband radome structure is described. The radome structure may include a central core layer comprising a first dielectric constant, an interior intermediate core layer adjacent to an interior side of the central core layer, comprising a second dielectric constant less than the first dielectric constant, an exterior intermediate core layer adjacent to an exterior side of the central core layer, comprising a third dielectric constant less than the first dielectric constant, and an interior outside core layer adjacent to an interior side of the interior intermediate core layer, comprising a fourth dielectric constant less than the second dielectric constant. In some examples of the radome structure described above may further include an exterior outside core layer adjacent to an exterior side of the exterior intermediate core layer, comprising a low dielectric constant.

A method and process is provided for manufacturing a glassed reinforced polymer composite laminate panel. The method and process includes the steps of providing a mold including a flexible polymer film; depositing a layer of gel coat on the flexible polymer film; curing the layer of gel coat to provide a semi-rigid intermediate panel; applying a layer of resin material overtop of the cured gel coat layer; laying a sheet of woven or non-woven surface veil material over top of the cured gel coat layer; laying a sheet of glass reinforced matte overtop of the surface film sheet; applying a second layer of resin material overtop the sheet of glass reinforced matte to form the glassed reinforced polymer composite laminate panel; and curing the glassed reinforced polymer composite laminate panel. The method for manufacturing the composite laminate panel can be a continuous process making a panel of indeterminate length.

A method for producing a component with a fibre-reinforced foam core has the steps of supplying a foam core having a first main surface and an opposite, second main surface, positioning at least one needle at the first main surface of the foam core, piercing the foam core with the needle, with the result that a needle tip penetrates through the first main surface into the foam core and then through the second main surface, hooking a reinforcing fibre into the needle tip, pulling the needle back, with the result that the reinforcing fibre is pulled through the foam core, and coating the reinforcing fibre with a resin while the needle is being pulled back.

A cosmetically altered fiberglass piece having an outer layer of curable gel-coat, an intermediate layer of textile fabric having a graphical element depicted thereon, and an inner layer of composite. A resin or epoxy is used to bond the layers to form the cosmetically altered fiberglass piece. Introduction of resin or epoxy is performed through one of a manual application, a vacuum infusion, or light RTM.

The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

A composite sandwich panel comprises a first composite skin, a second composite skin, a hollow cell core between the first composite skin and the second composite skin, and a first over-crush edge region with a first edge. The first edge has a first thickness at least 40% less than a nominal thickness of the composite sandwich panel. The first over-crush edge region has a length of at least 0.25 inches over which a thickness of the composite sandwich panel decreases.

Systems and methods are provided for fabricating composite parts. One embodiment is a method of forming a composite part. The method includes laying up opposing composite facesheets, placing a viscous material between the facesheets, increasing a distance between the facesheets, and solidifying the facesheets and the viscous material into an integral composite part.

The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

Described are methods and systems for a composite structure that allows for out of autoclave curing. Due to the layout of the composite structure, voids within the composite structure, formed out of autoclave, is reduced. The composite structure includes a composite laminate and one or more infusion films. The composite laminate includes a plurality of fiber tows that each include a plurality of fiber strands and a resin. The resin has a first viscosity within a first temperature range. The infusion film is disposed on a surface of the composite laminate and has a second viscosity lower than the first viscosity within the first temperature range. Methods of curing the composite structure are also described.

Provided are a method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material, a unidirectionally aligned discontinuous fiber reinforcement composite material, and a sandwich structure. The method for preparing a unidirectionally aligned discontinuous fiber reinforcement composite material comprises discontinuously aligning short fibers on a polymer substrate in one direction by using an air-laid method.