An end of arm tool (EOAT) for use during manufacture of parts using one or more pre-impregnated composite plies is disclosed. In an embodiment, the EOAT includes a mechanical gripper arrangement with first and second fingers configured to supply a compressive force to grip a pre-impregnated composite ply therebetween. At least one of the first and second fingers include a roller member to engage opposite surfaces of the pre-preg ply and supply a compressive gripping force. The roller member on either or both the first and second fingers preferably include a torque regulator to selectively adjust an associated roller member's resistance to rotation via supply of a rotational torque resistance.

A structural member for an aircraft or spacecraft has at least one fiber plastic composite, the fiber plastic composite having at least one or a plurality of plies. The structural member also has at least one pre-stressing means providing internal stresses to the fiber plastic composite. The fiber plastic composite and the pre-stressing means are configured and arranged to form a balanced system the internal stresses of which are essentially balanced to zero in a cured state of the said system. The balanced system of the structural member is able to counteract loading stresses exerted to the airframe in service such, that a damage caused by the loading stress is easily detectable visually.

A structural member for an aircraft or spacecraft has at least one fiber plastic composite, the fiber plastic composite having at least one or a plurality of plies. The structural member also has at least one pre-stressing means providing internal stresses to the fiber plastic composite. The fiber plastic composite and the pre-stressing means are configured and arranged to form a balanced system the internal stresses of which are essentially balanced to zero in a cured state of the said system. The balanced system of the structural member is able to counteract loading stresses exerted to the airframe in service such, that a damage caused by the loading stress is easily detectable visually.

A composite material blade molding method is for molding a composite material blade by curing a prepreg. The composite material blade has a back-side blade member and a belly-side blade member which are superposed and joined. The composite material blade molding method includes: a lamination step for forming a back-side laminate in a back-side molding die and forming a belly-side laminate in a belly-side molding die; an inner surface cowl plate disposition step for disposing an inner surface cowl plate for maintaining an inner space formed by the back-side laminate and the belly-side laminate; a die mating step for die-mating the back-side molding die and the belly-side molding die and disposing a foaming agent in the inner space maintained by the inner surface cowl plate; and a curing step for heating and expanding the foaming agent and heat-curing the back-side laminate and the belly-side laminate.

A composite material blade molding method is for molding a composite material blade by curing a prepreg. The composite material blade has a back-side blade member and a belly-side blade member which are superposed and joined. The composite material blade molding method includes: a lamination step for forming a back-side laminate in a back-side molding die and forming a belly-side laminate in a belly-side molding die; an inner surface cowl plate disposition step for disposing an inner surface cowl plate for maintaining an inner space formed by the back-side laminate and the belly-side laminate; a die mating step for die-mating the back-side molding die and the belly-side molding die and disposing a foaming agent in the inner space maintained by the inner surface cowl plate; and a curing step for heating and expanding the foaming agent and heat-curing the back-side laminate and the belly-side laminate.

Systems and methods are provided for utilizing support tools for forming laminates. One embodiment is a system that includes a pair of dies that hold a multi-layer laminate over a gap, a male die that presses the laminate into the gap causing the laminate to change shape, and a support tool inserted into the gap beneath the laminate. The support tool includes a base that extends in a lengthwise direction, struts fixedly attached to the base that project upward from the base and are distributed along the lengthwise direction, and a cap that is slidably attached to the struts, and that covers the struts to form an upper surface of the support tool. Each of the struts rises from the base to the cap.

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 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.

To improve the range of application of manufacturing methods for fiber-reinforced polymer or metal hybrid composite components, and preferably to enable the introduction of fiber bundles into a larger number of geometries, such as branches, merging points and intersections, a production method for producing a component including a composite material with a fiber reinforcement which is formed from fiber bundles and resin is disclosed. A component body with tube-like cavities is initially provided. Curable resin is introduced into the cavities. A pulling apparatus for the fiber bundles is also inserted into at least one of the cavities. The pulling apparatus includes at least one pulling member suitable for pulling the fiber bundles and transmitting compressive force. As a result of pulling of the pulling member, the fiber bundles are pulled into the cavities.

Methods to increase structural performance, strength, and durability of textile-reinforced composite materials are provided. The textile reinforcement may be knitted, for example, in a flat bed weft knitting machine. The method may include pre-stressing a textile reinforcement preform by applying tension. A polymeric precursor may be introduced to the pre-stressed textile reinforcement preform. The polymeric precursor may then be cured or consolidated, followed by releasing of the applied tension to form the composite article comprising polymer and the pre-stressed textile reinforcement. In other aspects, a composite article is provided that has a pre-stressed textile reinforcement structure and a cured polymer. The textile reinforcement may be a knitted, lightweight, seamless, unitary structure. The knitted reinforcement structure may have distinct first and second knitted regions with different levels of pre-stress, thus providing enhanced control over strength, rigidity, and flexibility of the composite article.