A process for manufacturing a structural component made of composite material comprising a skin and at least one stiffening stringer applied rigidly and integrally to one face of the skin. The process comprises a) arranging, on a tool, a plurality of first layers of uncured or pre-cured composite material, forming the stringer and having a raised portion protruding from at least one flange; b) arranging, on the tool, a plurality of second layers of uncured or pre-cured composite material forming the skin; c) making a face of the skin and the flange of the stringer adhere to each other; d) applying a predetermined temperature and pressure on the assembly to compact the layers together, possibly curing the uncured material and rigidly joining the skin to the stringer; and e) performing a cutting operation on the free end side edge/s of the flange in a slanted direction.

A process for manufacturing a structural component made of composite material comprising a skin and at least one stiffening stringer applied rigidly and integrally to one face of the skin. The process comprises a) arranging, on a tool, a plurality of first layers of uncured or pre-cured composite material, forming the stringer and having a raised portion protruding from at least one flange; b) arranging, on said tool, a plurality of second layers of uncured or pre-cured composite material forming said skin; c) making a face of said skin and flange adhere to each other; d) applying predetermined temperature and pressure on the assembly, possibly curing the uncured material and rigidly joining said skin to said stringer; e) performing a cutting operation on the free end side edge/s of said flange; and f) cover said end side edge/s of the end of said flange with a coating of composite material.

A method for fabricating a preform for a portion of an aircraft includes acquiring a sheet of broad good fiber reinforced material, trimming the sheet to form layup pieces having boundaries, placing the boundaries into alignment, arranging the layup pieces in a layup pattern to form a ply, performing a placement operation that transports the layup pattern onto a layup mandrel, and shaping the layup pattern into conformance with a contour of the layup mandrel.

The method for producing an assembly is a method for producing an assembly equipped with a member to be reinforced (20), a reinforcing member body (41), and a filler (42), wherein the reinforcing member body (41) has a pair of flanges (44) arranged spaced on the surface (20B) of the member to be reinforced (20), a web (45), and a connection portion (46) which connects the flanges (44) and the web (45) and forms a filler space (V) with the surface (20B). The method for producing an assembly includes a step for inserting a filler (42) into the filler space (V), a step for attaching a crack control member (43) to cover the end of the filler (42), a step for joining the flanges (44) and the member to be reinforced (20), and a step for curing at least the member to be reinforced (20).

In an example, a composite stringer is described. The composite stringer includes a skin flange having a first gage, a top flange having a second gage, and a web having a third gage and extending between the skin flange and the top flange. The skin flange is configured to be coupled to a support structure. The support structure includes at least one of a skin of a vehicle or a base charge. The second gage of the top flange is greater than the first gage of the skin flange and the third gage of the web. The skin flange, the top flange, and the web include a plurality of plies of composite material.

A rim portion of a composite wheel comprises a shaped annulus formed about a central axis of rotation of the composite wheel and having a circumferential axis extending circumferentially about the central axis and around the rim portion, said rim portion having a fibre layup comprising a stacked laminate formed from alternating layers of: a hoop tow layer comprising elongate fibre tow in which the fibres are substantially aligned with the circumferential axis of the rim portion, the hoop tow layer being formed from at least one annularly wound elongate fibre tow; and a bias ply layer comprising at least one fibre ply in which the fibres are substantially orientated at an angle of +Θ or −Θ to the circumferential axis of the rim portion, wherein Θ is from 26° to 40°.

A composite stiffener for a stiffener reinforced panel is disclosed. The stiffener has a longitudinal direction and a run-out region which terminates at an end of the stiffener. The stiffener also has a constant section region inboard of the run-out region in the longitudinal direction and having a constant cross section transverse to the longitudinal direction with a crown between adjacent foot portions. The run-out region has a changing cross section transverse to the longitudinal direction with a crown between adjacent foot portions and the crown reduces in height towards the end of the stiffener forming a ramp. The composite stiffener comprises a number of blankets of non-crimp fabric layers.

A wind turbine blade shear web comprises an elongate panel (28) having a first side and an opposing second side and a longitudinally extending flange (30a, 30b) arranged along a longitudinal edge of the panel. The flange comprises a plurality of elongate flange sections (46) arranged along the first side of the panel and integrated therewith. Each flange section comprises a plurality of elongate flange elements arranged one on top of another and offset from one another in a longitudinal direction of the flange section (46) such that the offset between the flange elements defines a tapered portion at each of a first and second longitudinal end of the flange section. The tapered portions of longitudinally adjacent flange sections overlap to define at least one scarf joint between said adjacent flange sections.

A method of forming a wind turbine blade shear web flange section (36) by resin transfer moulding comprises providing a mould assembly (84) comprising a mould surface (86) defining a mould cavity and arranging a plurality of elongate flange elements (46) with the mould surface in an array (80) such that the flange elements are positioned one on top of another with first and second longitudinal ends (56,60) of each flange element longitudinally offset from respective first and second longitudinal ends of a neighbouring flange element so as to form a tapered portion (58,62) at each of a first and second longitudinal end of the flange section (36). A The method further comprises injecting resin to the mould cavity and curing the array of flange elements in a resin matrix to form a cured flange section having a laminate construction.

A method of forming a tool includes applying a first build ply to an initial ply. A second build ply is applied to the first build ply. Successive build plies are applied to build on the second build ply, the successive build plies including a medial section of build plies and a last build ply. A surface defined by the last build ply, the first build ply, and leading edges of the build plies therebetween define a substantially curvature-continuous surface profile extending between a first segment and a second segment. A shape of the substantially curvature-continuous surface profile is determined based on an adjusted ply drop ratio for at least a portion of the successive build plies.