Systems, methods, and apparatus are disclosed for controlling a flow of a material through a vehicle component. In some embodiments, the methods include determining a first plurality of dimensions and a second plurality of dimensions associated with a flow medium based on one or more flow properties of the vehicle component, the flow medium including a plurality of baffle layers and a plurality of spacers. The methods may further include generating at least one baffle layer based on the first plurality of dimensions, and generating at least some of the plurality of spacers based on the second plurality of dimensions, the plurality of spacers being positioned on top of the at least one baffle layer.

A process for manufacturing a fibre-plastic composite with a secured fibre orientation, wherein continuous fibres or long fibres are oriented and sheathed with a matrix, characterized by the steps of (a) providing a mold comprising at least one flow channel, (b) introducing the continuous fibres or long fibres into the at least one flow channel, (c) positioning and orienting the continuous fibres or long fibres in the at least one flow channel by way of a pressure gradient in the flow channel, (d) sheathing the continuous fibres or long fibres with a matrix.

Providing blanks from a fibre web includes removing the blanks from removal regions and depositing the blanks in at least one deposit element. The blanks are then removed from the deposit elements in accordance with a sequence predefined by a layer-by-layer construction of a workpiece. The blanks that are individually removed from the removal regions are stacked on top of one another in the deposit elements in a sequence that corresponds to a layering sequence of the blanks in the workpiece. The blanks are then successively removed individually from the deposit elements in a sequence that is reversed with respect to the layering sequence of the blanks in the workpiece and are stacked on top of one another in a storage element before being successively removed from the storage element in the sequence predefined for constructing the workpiece layer-by-layer and inserted into a mould for producing the workpiece.

A method of forming a fibre article, comprising: providing a former having a contoured forming surface; locating a fibre preform between a first diaphragm and a second diaphragm, the second diaphragm being offset from the forming surface; drawing a vacuum between the first and second diaphragms so as to hold the preform captive between the diaphragms; displacing the second diaphragm towards the former so as to bring the second diaphragm into partial contact with the former; drawing a vacuum between the second diaphragm and the former so as to bring at least a part of the second diaphragm adjoining the preform into conformity with the forming surface; and setting the preform in its configuration; wherein: the fibre preform comprises one or more substantially inextensible fibres extending linearly in a first direction; the forming surface comprises a concavity and prominences on either side of the concavity; and the step of bringing the second diaphragm into partial contact with the former comprises bringing the second diaphragm into contact with the prominences whilst the second diaphragm does not fully contact the concavity and with the substantially inextensible fibres extending from one of the prominences to the other.

A method and apparatus for constructing a tubular assembly 40 comprising an inner portion (24) and a further portion (23) surrounding the inner portion. The inner portion (24) comprises reinforcement (37) and the further portion (23) being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus comprises an assembly station (220) comprising a wall (253). The apparatus comprises means for advancing the inner portion (21) along a first path (231) extending passed the wall (253), and means for advancing the strip (50) along a second path (232) and causing the strip to encircle the wall (253) and thereby wrap about and surround the inner portion (21). The apparatus further comprises means (321) for introducing resinous binder into the reinforcement (37) as the strip (50) is being wrapped about the inner portion (21).

A method and apparatus for shaping, compacting, and supporting a composite material (C) contained between two flexible membranes (G, F) and capable of being stretched over a porous mold (A) are described. The apparatus enables the use of inexpensive mold despite the high pressures used. A counter-mold (M) having the same characteristics as the mold can be used in certain instances. The equipment enables the use of a plurality of molds and counter-molds during one manufacturing cycle.

A hybrid mold includes (a) an Invar® eggcrate structure, (b) an Invar® interim working surface and (c) a CF composite material overlay. The eggcrate and interim working surface are welded or otherwise connected together to form a unitary base mold. The CF overlay is bonded to the interim working surface. The CF overlay is easily reconfigurable and can be replaced without destroying the integrity of the base mold.

A method for producing a component from a fiber composite. A number of layers of a dry fibrous material are stacked to form a pile, the pile is covered by a thermoplastic film in a gas-tight manner, the inner space occupied by the pile within the film is pumped dry and the layers are fixed to form a preform that is stable during transport, the preform is reshaped, a liquid thermosetting material is inserted into the inner space by infiltration of the fibrous material, and the preform is hardened with the infiltrated fibrous material to form the finished component, the film binding permanently as the surface. The invention also relates to a component produced in such a way, and to a corresponding preform. The production method provides a process-integrated surface finishing of the fiber composite. The surface properties are created by the bound thermoplastic film.

Methods for manufacturing a turbomachine composite part, such as a fan blade, are provided. The composite part has a fibrous structure with a three-dimensional fibrous preform coated with a surface fibrous web, and which is embedded in a polymer matrix The methods include: forming the surface web in a cavity of a mold in order to shape it, wetting and forming the preform on the surface web in order to shape it, and closing the mold, drying the fibrous structure, and injecting thermosetting resin into the mold in order to form said polymer matrix. The surface web is wetted before and/or during the forming thereof.

A repair patch is for a composite material to repair a part to be repaired which is a repair target of the composite material. The patch includes a patch main body that is formed by laminating a plurality of fiber reinforced preforms in a thickness direction, and has a bonding surface to be bonded to the part to be repaired; and a removal layer that is provided on the bonding surface to be peelable off from the patch main body. The bonding surface includes an inclined surface that is inclined with respect to the thickness direction of the patch main body. The removal layer includes a processed portion that causes the removal layer to have a shape complementary to a shape of the inclined surface of the patch main body.