A fiber-reinforced polymer composite assembly, that includes a plurality of sheets, each formed from a composite mixture including a fibrous material and a resin, wherein each of the first plurality of sheets are cut to one or more predetermined dimensions. The plurality of sheets are configured to form a stack, and wherein the stack is shaped by positioning the stack on a mold and pressing and consolidating/curing the stack to form a doubly-curved geometric shape. An insert may be positioned between the plurality of sheets, prior to the pressing and consolidating/curing, wherein the fibrous material may in include paper, and wherein the resin includes one of a thermoset resin or a thermoplastic resin.

A system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

A method for forming a composite part involves forming a layup comprising (a) preforms/flat form-factor feedstock, either of which includes a plurality of fibers and a matrix precursor, and (b) a differential-melt polymer. The matrix precursor and the differential-melt polymer differ as to at least one of thermal properties and rheological properties. The layup is subjected to controlled application of heat and pressure to melt the matrix precursor and differential-melt polymer. The polymers are then cooled to form a composite part that displays properties attributable to all the constituents. As a function of a variety of factors, the resulting part can be homogenous or heterogenous, and the properties can be localized or global throughout the part.

A method for forming a composite part involves forming a layup comprising (a) preforms/flat form-factor feedstock, either of which includes a plurality of fibers and a matrix precursor, and (b) a differential-melt polymer. The matrix precursor and the differential-melt polymer differ as to at least one of thermal properties and rheological properties. The layup is subjected to controlled application of heat and pressure to melt the matrix precursor and differential-melt polymer. The polymers are then cooled to form a composite part that displays properties attributable to all the constituents. As a function of a variety of factors, the resulting part can be homogenous or heterogenous, and the properties can be localized or global throughout the part.

A method for closing an injection mold for manufacturing a revolution part made of composite material, the mold including a mandrel supporting a fiber preform and angular sectors comprising an annular base to come into contact with the fiber texture, the annular base extending between first and second side edges along a circumferential direction. The method includes successive positioning and fixing the angular sectors on the mandrel, the annular base of each sector compacting the fiber preform portion present oppositely, the side edges of the annular base of each angular sector being in contact with the side edges of the annular base of the adjacent sectors. Before the positioning and fixing of the angular sectors on the mandrel, strip s are placed on the exposed surface of the fiber preform, each strip covering an area of the fiber preform located facing a junction area between two adjacent angular sectors.

A method of heating a tool assembly includes the step of joining a first piece of the tool assembly with a second piece of the tool assembly via a first joint portion and a second joint portion. The method further includes the step of inserting a fastener through the first joint portion and the second joint portion of the tool assembly. The method further includes the step of applying heat to the tool assembly, wherein upon heating, interlock surfaces of the first joint portion and the second joint portion tighten against each other.

An induction curing system comprises a slip sheet and a power supply. The slip sheet comprises a layup surface configured to receive a composite material, a tool interface surface configured to interface with an upper surface of a tool, a rigid body extending between the layup surface and the tool interface surface, and an induction coil circuit within the rigid body of the slip sheet. The induction coil circuit is configured to heat the layup surface to a temperature sufficient to cure the composite material. The induction coil circuit has a diameter selected to generate heat using a power supply having a frequency below 150 kHz. The rigid body is configured to support the composite material during transport of the composite material. The power supply is coupled with the induction coil circuit, the power supply is selected based on the diameter of the induction coil circuit.

An induction curing system comprises a slip sheet and a power supply. The slip sheet comprises a layup surface configured to receive a composite material, a tool interface surface configured to interface with an upper surface of a tool, a rigid body extending between the layup surface and the tool interface surface, and an induction coil circuit within the rigid body of the slip sheet. The induction coil circuit is configured to heat the layup surface to a temperature sufficient to cure the composite material. The induction coil circuit has a diameter selected to generate heat using a power supply having a frequency below 150 kHz. The rigid body is configured to support the composite material during transport of the composite material. The power supply is coupled with the induction coil circuit, the power supply is selected based on the diameter of the induction coil circuit.

A system and method for forming a composite part. The apparatus comprises a sleeve that molds a composite material. The sleeve has a first face and a second face. The second face has features to mold the composite material. The first face comprises a first inclined surface having an angle less than about 90 degrees and greater than about 0 degrees.

A thermoforming method includes forming a skin comprising a plurality of plies thermoplastic resin and fiber, securing an edge of the skin to a mandrel, heating, via a heating element, the skin to a forming temperature, moving a thermoforming apparatus with respect to the mandrel, rolling at least one roller of the thermoforming apparatus along the skin in a direction away from the clamped edge of the skin in response to the thermoforming apparatus moving with respect to the mandrel, and in response to the at least one roller of the thermoforming apparatus rolling along the skin, compressing the skin between the at least one roller and the mandrel, consolidating the plurality of plies of material, and bending the skin to conform to a shape of the mandrel. The consolidated and formed skin is then cooled and removed from the mandrel.