A method for fabricating a composite material assembly includes: a) providing an assembly system, b) laying down a first module on a first mold, the first module comprising a first laminate covering a first laminate support structure, c) laying down a second module on a second mold, the second module comprising a second laminate covering a second laminate support structure and extending over the at least one removable insert, d) removing the at least one removable insert from the second mold, and e) assembling the first mold with the second mold while overlapping a section of the second laminate extending over the at least one removable insert over the first laminate.

A mounting tool (1) for mounting a friction-welding boss (9), wherein the mounting tool (1) includes a drive shaft (2) with a first end section (3) adapted to create a detachable force coupling with the friction-welding boss (9) or an adapter and a holder is arranged spring-loaded at the first end section (3) and at least one cutting means (6) is arranged at the holder (5). A milling adapter (10) includes a first end section (11) adapted to create a detachable force coupling with a mounting tool (1), and a second end section (12) including at least one cutting means (13).

A method of anchoring a connector in a heterogeneous first object that includes a first building layer and, distally of the first building layer, an interlining layer. The method includes providing the first object and the connector, which includes thermoplastic material in a solid state; contacting the connector with the first building layer; applying a first mechanical pressing force to the connector until the first building layer is pierced by the connector and a distal portion of the connector reaches into the interlining layer; applying a second mechanical pressing force and mechanical vibration to the connector until a flow portion of the thermoplastic material is flowable and penetrates structures of the first object, and a distally facing abutment face of the head portion abuts against the metal profile in a region next to the opening; and letting the thermoplastic material resolidify to yield a positive-fit connection.

Joints for joining panels together, such as for joining honeycomb sandwich panels used in aerospace applications, and methods of joining said panels are disclosed. In some examples of disclosed joints, a first panel and a second panel can be joined together to form a joint. The first panel can be a flat panel that includes a rabbet formed along a first longitudinal edge, and the second panel can be a curved panel that includes a notch formed along a second longitudinal edge. In forming the joint, a portion of the rabbet can be positioned within the notch, and the flat panel and curved panel can be oriented at a non-parallel and non-perpendicular angle to one another. Adhesive can be applied along the rabbet and/or the notch in order to secure the joint.

An insert for use in a sandwich-type structure is provided that includes a housing defining an internal bore, a proximal flange, opposed distal flanges, and an exterior wall portion extending between the proximal flange and the opposed distal flanges. The opposed distal flanges define lateral walls arranged tangentially with a wall of the internal bore. A nut is disposed within the internal bore of the housing and configured to float therein, the nut defines a truncated flange and a hollow shaft extending from the truncated flange. The hollow shaft of the nut defines internal threads and an exterior wall, the exterior wall having a diameter at least equal to a thread lock diameter. A cap is configured for engagement with the opposed distal flanges such that the nut is floatingly captured within the internal bore of the housing.

A system and method for fabricating a composite material assembly. The components of the assembly originate from more than one mold while providing curing or solidifying under heat and vacuum in one step only, preferably with a composite material in a pre-preg form which does not require autoclave treatment. A removable insert is removed from a second mold prior to assembly of a first mold to the second mold. A section of a laminate extending over the removable insert overlaps over an adjacent laminate after closing and assembly of the first mold onto the second mold.

A lightweight support structure includes a composite sandwich panel having a first face sheet and a lightweight core attached to the face sheet and an essentially rotationally symmetric cut-out extending through the first face sheet and into the lightweight core. The cut-out has an essentially rotationally symmetric inner cut-out and outer cut-out arranged essentially concentric with respect to each other, providing for a support there between. The support has a core support cut from the lightweight core and a support face sheet disc on top, cut from of the first face sheet. A rotationally symmetric insert is fitted into the cut-out for load application and/or anchorage of various components into and onto the sandwich panel.

An automated fastener insert installation system for composite panels is provided. A first module receives and secures a composite panel with respect to an origin of a first coordinate system, wherein the composite panel has opposed major surfaces and defines an insert-receiving orifice extending through one of the major surfaces, and is secured such that one of the major surfaces is externally accessible. A second module engages each of a plurality of fastener inserts with an installation aide. Third module determines a configuration of the orifice defined by the composite panel, selects a corresponding one of the fastener inserts engaged with the installation aide, inserts the selected fastener insert into the orifice, and dispenses an adhesive material through the installation aide and into the orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the orifice. Associated systems are also provided.

Joints for joining panels (60, 62) together, such as for joining honeycomb sandwich panels used in aerospace applications, and methods of joining said panels are disclosed. In some examples of disclosed joints, a first panel and a second panel can be joined together to form a joint. The first panel (60) can be a flat panel that includes a rabbet (80) formed along a first longitudinal edge, and the second panel (62) can be a curved panel that includes a notch (86) formed along a second longitudinal edge. In forming the joint, a portion of the rabbet (80) can be positioned within the notch (86), and the flat panel (60) and curved panel (62) can be oriented at a non-parallel and non-perpendicular angle to one another. Adhesive (99) is applied along the rabbet (80) and/or the notch (86) in order to secure the joint.

An insert, a floating nut and methods for use thereof in a panel of an aircraft are presented. Specifically, an insert includes a housing defining a cavity. An aperture is further defined in a first end of the housing and a semi-spherical portion is defined at a second end of the housing. A pair of vent openings are also defined on opposing sides of the first end of the housing.