The disclosure discloses apparatus and methods for repairing defects such as porosity and/or edge delamination in composite laminates by infusion of flowable matrix material. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate through the use of a formed hole extending at least partially through the composite laminate. In some embodiments, methods disclosed herein comprise infusing the flowable matrix material into a space in the composite laminate in a stepwise manner in order to obtain more complete filling of such space.

A method for producing a three-dimensional preform from an intermediate preform blank (30, 70), which contain undulations (31) in a portion thereof. The preform blank (30, 79) may be formed on a tool surface (60) containing undulations (61) using an automated placement method such as Automated Tape Laying (ATL) or Automated Fiber Placement (AFP), in which narrow-width strips of material are dispensed side-by-side. Various preform blanks (30, 70) and molding tools (10, 50, 80) have been designed to produce shaped preforms having generally C-shape and Z-shape cross-sections.

The present invention provides a tool 1 for curing a composite component, the tool comprising a lay-up surface 8 for laying-up layers of an uncured composite component, a cover assembly 9 for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port 25 for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating element 15, 53 within the sealed zone for heating the uncured composite component. The invention also provides a method of manufacturing a composite component and a composite component. The composite component may form at least part of a piece of aircraft furniture, such as an aircraft seat shell.

An article-forming tool comprises an elongate jig having a predefined shape, an elongate flexible vise configured to hold a fiber-composite article of a predefined cross section, and a spacer system. The vise opposes the jig; it includes a series of clamp segments and a flexible spline sheet configured to conform controllably to the shape of the jig. The clamp segments are arranged side-by-side along a length of the vise, each clamp segment comprising a set of platens configured to hold a corresponding longitudinal segment of the article. The flexible spline sheet extends through the series of clamp segments, between opposing platens. The spacer system is configured to control the conformation of the spline to the shape of the jig.

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

A method of forming a composite member, includes: applying pressure and heat with a compaction tool to a portion of an uncured composite member to decrease a thickness of the portion, the heat applied with the compaction tool being at a temperature less than a curing temperature of the uncured composite member; and curing the uncured composite member after applying pressure and heat.

A method of fabricating a composite structure is presented. The method comprises laying up a plurality of composite plies over a layup mandrel; positioning a first caul plate and a second caul plate over the plurality of composite plies, leaving composite material exposed; removing at least part of the composite material exposed between the first caul plate and the second caul plate to separate a first composite section from a second composite section; curing the first composite section and the second composite section to form a first composite part and a second composite part; and removing the first composite part and the second composite part from the layup mandrel immediately following curing.

According to one implementation, a preform shaping apparatus includes a rigid mold and a pressurizing jig. The rigid mold has a shape corresponding to a shape of a preform which has been shaped. The pressurizing jig presses an unshaped material of the preform to the rigid mold at different positions and different timings. Further, according to one implementation, a method of shaping a preform includes: producing the shaped preform by pressing an unshaped material of the preform to a rigid mold at different positions and different timings; and using a pressurizing jig for pressing the material. The rigid mold has a shape corresponding to a shape of the preform. The pressurizing jig is adapted to apply pressures on the material at the different positions and the different timings.

A device for manufacturing a composite component including a tool with a first and second sections forming first and second confinement surfaces, the sections movable relative to each other into and out of a fastening configuration. The device includes a closing mechanism with a closing section. In the fastening configuration, the first confinement surface and the second confinement surface face one another, and the sections and the closing mechanism are arranged such that a cavity is formed between the sections and the closing mechanism. The closing section is transferable from an open configuration into a closed configuration. In the closed configuration, the third confinement surface extends along a plane perpendicular to the first and second confinement surfaces, wherein, when the closing mechanism is heated from a first temperature to a second temperature, the closing section transfers from the open configuration into the closed configuration at a predefined temperature.

A system for making highly contoured composite stringers, including a flexible stringer assembly to support an uncured composite stringer; and a contoured mandrel to contour the uncured composite stringer into a highly contoured shape, wherein the contoured mandrel comprises one or more curvatures with a radius of 100 inches or less along at least one of an x, y, or z axis.