There is provided a method of producing a wind turbine rotor blade. A mold for a spar cap is provided. The mold has at least one negative cap edge. Glass fiber layers are laid in the mold and in the negative cap edge to achieve transverse scarfing at the ends of the glass fiber layers in such a way that a spar cap having a negative scarfing is provided. The spar cap having the negative scarfing is installed in a core material of the rotor blade.

A wind turbine blade and a method of moulding a wind turbine blade tip section. The overall wind turbine blade has an elongate structure extending in a radial sense in a finished wind turbine. The blade comprises a fairing that one is supported along its length by a spar extended along the full length of the fairing from the root end to the tip. The fairing is in two parts with a main part extending from the root for most the of the longitudinal length of the blade and the tip section forming the remainder of the blade.

A belt for suspending and/or driving an elevator car includes a tension member extending along a length of the belt, the tension member including a plurality of fibers bonded in a first polymer matrix, the plurality of fibers extending parallel to and discontinuous along a length of the belt and arranged with one or more lengthwise extending gaps between lengthwise adjacent fibers. A jacket substantially retains the tension member. A method of forming a tension member for an elevator system belt includes arranging a plurality of fibers into a fiber bundle. The plurality of fibers extend parallel to a length of the belt and have one or more lengthwise extending gaps between lengthwise extending fibers. The plurality of fibers is bonded to a first polymer matrix.

A vehicle roof stiffener includes at least one fiber reinforced polymer (FRP) portion and at least one metal or metal alloy portion. The FRP portion includes at least one transition structure including a metal or a metal alloy. At least some of the fibers of the FRP portion are embedded in the transition structure. The metal or metal alloy portion is secured to the transition structure of the FRP portion. In an example vehicle roof stiffener, the metal portion extends parallel to a longitudinal axis of a vehicle, and the FRP portion extends transverse to the longitudinal axis. The example vehicle roof stiffener may include a front FRP portion, a rear FRP portion, and two metal side portions. The metal side portions and the FRP portions may be joined by welding the transition structures to the metal portions.

Composite laminate structures are produced using partially cured parts. Partial curing of the parts is achieved by applying a catalyst to regions of the parts that are to be fully cured. These regions cure at a lower-than-normal temperature while remaining regions of the part remain uncured, allowing them to be co-bonded or co-cured to other structures.

A composite structure with an integrated hinge is disclosed. In various embodiments, the composite structure includes a plurality of layers of fiber reinforced polymer material; and a hinge structure comprising one or more layers of bendably flexible hinge material a first region of which is interleaved between adjacent layers of said layers of fiber reinforced polymer material comprising the composite structure and bonded to said adjacent layers by bonding material comprising said composite structure, and a second region of which extends beyond said layers of fiber reinforced polymer material comprising the composite structure.

A method for providing motor vehicle wheels made of composite material based on carbon fiber includes the steps of, dividing each wheel into a plurality of portions having small dimensions; providing a a first portion with the terminal edges designed to mate with corresponding edges of a respective second portion; mating the portions, arranging them subsequently within a respective mold whose shape and dimensions are conjugate with respect to those of the wheel to be manufactured; and bringing the mold and its contents to a predefined temperature. The method further includes injecting into the mold a resin in the liquid state, the resin being injected at high pressure and high temperature, forming the matrix of the composite that constitutes the wheel; maintaining the pressure and temperature of the mold within predefined ranges for a time interval that is required for the at least partial cross-linking of the resin; and extracting the wheel from the mold.

Walls of gas turbine engine casings, fan cases, and methods for forming walls, e.g., fan case walls, are provided. For example, a wall comprises a plurality of composite plies arranged in a ply layup. The wall is annular and circumferentially segmented into a plurality of regions that include at least one first region and at least one second region. The ply layup in the first and second regions is different such that the ply layup is non-axisymmetric. An exemplary fan case comprises an annular inner shell, a filler layer, an annular back sheet, and an annular outer layer. The back sheet is circumferentially segmented into a plurality of regions, including at least one first region and at least one second region, and comprises a plurality of composite plies arranged in a ply layup that is different in the first and second regions such that the ply layup is non-axisymmetric.

Composite laminate structures are produced using partially cured parts. Partial curing of the parts is achieved by applying a catalyst to regions of the parts that are to be fully cured. These regions cure at a lower-than-normal temperature while remaining regions of the part remain uncured, allowing them to be co-bonded or co-cured to other structures.

A method of manufacturing a hollow composite structure is provided. The method includes forming a first portion of the hollow composite structure having at least one open region and at least one wall, the at least one wall partially defining a hollow interior. The method also includes bonding a laminate shell to the first portion of the hollow composite structure proximate to at least one location of the wall to cover the open region and enclose the hollow interior. The method further includes disposing a second portion of the hollow composite structure over the laminate shell, the second portion comprising a plurality of plies. The method yet further includes curing the first portion and the second portion during a final cure.