A disclosed manufacturing method includes a step for draping a fiber reinforcement, into a plurality of superposed layers, a step for providing resin in the fiber reinforcement, and a step for polymerizing the resin. The method includes, prior to the draping step, a step for making cutouts with a predetermined shape in the fiber reinforcement, and during the draping step, the layers of fiber reinforcement are superposed by putting the cutouts facing each other, the whole of the cutouts of the superposed layers forming a housing at least for an insert.

According to one implementation, a prepreg lamination apparatus includes first and second rollers, a table, and a feed structure. The first roller sends out a first prepreg tape which is a part of material of an FRP. The second roller sends out a second prepreg tape which is another part of the material of the FRP. The table is for laminating the first and second prepreg tapes directly or indirectly. The feed structure is adapted to feed out the first and second prepreg tapes in a feeding direction by moving the first and second rollers relatively to the table while performing at least one of movement of the first roller relatively to the second roller, and rotation of at least one of the first and second rollers relatively to the table around an axis which is not parallel to each of rotation axes of the first and second rollers.

Disclosed is a method for producing components from fiber-reinforced thermoplastic on the basis of fiber tapes impregnated with matrix material. The method includes manufacturing a multitude of semi-finished products, each of which has a plurality of non-consolidated layers of fiber tapes. The semi-finished products are placed in a consolidation device in such a way that the semi-finished products are in direct contact with one another. The semi-finished products are then consolidated using the consolidation device and the semi-finished products are at least partially joined to one another during the consolidation process. The joined semi-finished products are then cut apart using a cutting device.

A method for manufacturing a high-pressure tank including a reinforcing layer in which rims of both ends of a tubular member and rims of a pair of dome members are joined to overlap each other in a radial direction includes producing the dome members and producing the tubular member. The producing of the dome members includes producing a wound body on a mandrel, curing a resin contained in the wound body, shaving the wound body after the resin is cured to reduce, toward a split line, thicknesses of the rims of the dome members to be obtained by splitting the wound body, splitting the shaved wound body into the dome members by cutting the wound body along the split line, and demolding the dome members from the mandrel.

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.

A three-dimensional printing system calculates a resin amount required to print a three-dimensional object by curing a liquid photo-curable resin and sequentially stacking layers of the cured resin each having a predetermined cross-sectional shape. The system includes a first storage section configured to store information of a three-dimensional object, and information of an auxiliary member that supports the three-dimensional object, a first calculation section configured to calculate a resin amount necessary to print the three-dimensional object and a resin amount necessary to print the auxiliary member based on the information of the three-dimensional object and the auxiliary member stored in the first storage section, an output section configured to output a first resin amount that is the sum of the calculated resin amounts necessary to print the three-dimensional object and the auxiliary member, and a three-dimensional printing apparatus.

The present invention relates to a deposition head provided with an assemblage comprising a of impregnated fibers arranged against a backing tape. The deposition head includes a slide and a movement actuator connected to the slide to move the slide in translation from a high position to a low position, said slide carrying a peeling roller, said backing tape extending over a circular arc against the peeling roller, said low position being configured so that said peeling roller presses said tape of impregnated fibers against a deposition surface only in the low position of the slide, said circular arc occupying a first angle in the low position of the slide and a second angle in the high position of the slide, said first angle being greater than said second angle.

A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160° C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

Described are novel composite structural panels and methods of forming such panels. In some examples, a method comprises wrapping a mandrel with a composite tape to form a composite tube. This wrapping operation allows forming composite tubular structures with any cross-sectional profiles defined by the mandrel. The wrapping is also used to control the fiber orientations in the composite tubular structures. The composite tube is then cut into composite tubular structures. In some examples, the composite tube is partially cured prior to the cutting, which allows removal of the mandrel while preserving the shape of the composite tube. This cutting operation allows forming composite tubular structures with different lengths, shapes, and orientations of the ends. The composite tubular structures are disposed on a support structure and are bonded to each other. In some examples, this bonding operation also involves final curing of the composite tubular structures.

Composite assemblies are described that include composite spars that are co-cured with one or more sacrificial members on their flanges, forming an integrated sacrificial surface for the composite spars. In one embodiment, the composite assembly includes a composite spar having a web and flanges that project from sides of the web. The composite assembly further includes a sacrificial member of composite materials co-cured with the composite spar on an outer surface of at least one of the flanges. In addition, the sacrificial member has an outer surface that has been machined into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface with the at least one skin panel.