The present invention includes methods of preparing a composite structure comprising: placing a first ply of a fibrous material with a curable material on a layup tool; adding one or more additional plies on the first ply, wherein each of the one or more additional plies has a perimeter that is different in size around the perimeter than a previous ply to form a taper; and curing the composite structure, wherein the curable material is selected to minimize, limit, control, or eliminate the outflow of the curable material along the perimeter of the composite structure during the curing step.

Methods of repairing a defect in a polymeric composite structure are provided. The methods include disposing a patch over a defect in a polymeric composite structure; disposing a textured sheet over the polymeric patch, applying pressure to the polymeric patch and the textured sheet; and heating the polymeric patch. The textured sheet has a surface texture that is a negative of a surface texture of the polymeric composite structure.

A method for assembling a stiffened composite structure includes a step of positioning a plurality of dry fibers along a first side of a pre-preg composite laminate skin element wherein the pre-preg composite laminate skin element is dimensionally changeable. The method further includes a step of positioning an interlayer between the plurality of dry fibers and the first side of the pre-preg composite laminate skin element and a step of infusing the plurality of dry fibers with a resin forming a plurality of infused fibers. The method also includes a step of co-curing the pre-preg composite laminate skin element and the plurality of infused fibers.

A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation. The plurality of smart susceptor heater blankets may be supported by a deployment system that lowers the plurality of smart susceptor heater blankets toward, and raises the plurality of smart susceptor heater blankets away from, a working surface.

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a selected location for placing the composite part on the tool, to direct the dispensers to apply a mold release agent onto the tool based on the selected location, to apply a sealant onto the tool proximate to the selected location, to lay up a ply of constituent material for the composite part atop the mold release agent at the selected location, to apply a pressure pad material atop the constituent material, to apply a breather material atop the pressure pad, and to apply vacuum bag material atop the ply proximate to the selected location to cover the ply as well as the sealant.

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a location for placing the composite part on the tool, and to direct the dispensers to lay up a laminate of constituent material for the composite part at the location. The controller is also able to direct the dispensers to spray vacuum bag material atop the laminate to form a vacuum bag that covers the laminate.

Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting an end caul comprising a structure of sintered material surrounding volumes of unsintered particles, creating a laminate comprising fibers within a resin matrix, placing the end caul in contact with an end of the laminate, and processing the laminate.

A jig includes mold parts that have a contact surface of a cylindrical part of a material to be molded having a shape complying with the inner peripheral surface of the cylindrical par and are arranged in a direction crossing one direction; a bladder having on a side opposite to the contact surfaces of plurality of mold parts relative to the mold parts, capable of accommodating a fluid therein, and expandable/retractable according to a pressure of the accommodated fluid; a joining part that joins the plurality of mold parts and the bladder; and a connection part that connects a one-side mold part and an another side mold part adjacent to the one-side mold part among a plurality of mold parts to each other and restricts an interval between the one-side mold part and the other-side mold part in a direction crossing the one direction with a prescribed range.

A flexible caul for applying pressure to a part comprises a caul member having a plurality of spaced apart gaps therein to provide the caul member with flexibility, and a flexible covering that limits flexing of the caul member.

A method of manufacturing a flexible element configured for pressing against composite material received on a mold surface of a mold during cure, including placing a porous material over the mold surface, forming a sealed enclosure containing the mold surface and the porous material, infusing a curable liquid material such as silicone in liquid form into the enclosure under vacuum and through the porous material, curing the liquid material to form the flexible element, and opening the enclosure and disengaging the flexible element from the mold. In a particular embodiment, the flexible element is a pressure pad.