Disclosed herein is a device for producing composite components including at least one wound fiber reinforced polymer layer, including: a support with a first holding device and a second holding device for mounting a liner in between, where the first and the second holding device are such that the liner can rotate around a central rotation axis which extends through the first holding device and the second holding device, and at least two movable arms for feeding a fiber structure, where the support is established such that the liner can be moved axially parallel to the central rotation axis and each movable arm for feeding the fiber structure can be moved perpendicular to the central rotation axis. Further disclosed herein is a process for producing composite components using the device.

In an example, a composite structure having a variable gage is described. The composite structure includes a first end having a first gage, a second end having a second gage, which is less than the first gage, a plurality of continuous plies, and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. Each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern.

In an example, a composite structure having a variable gage is described. The composite structure includes a first end having a first gage, a second end having a second gage, which is less than the first gage, a plurality of continuous plies, and a plurality of drop-off plies. Each continuous ply extends from the first end to the second end. Each drop-off ply includes a tip having a tapered shape. Each drop-off ply extends from the first end to a respective position of the tip of the drop-off ply between the first end and the second end. The tips of the plurality of drop-off plies are arranged in a monotonically-inward pattern.

The present invention relates to a composite material comprising one or more fibre layers composed of a fibre material and an aromatic polycarbonate-based matrix material. The fibre layer(s) is/are embedded in the matrix material. The present invention further relates to a process for producing these fibre composite materials, to multilayer composite materials comprising several layers of fibre composite material, and to the use of the composite materials for production of components or housing components or housings, and to the components, housing components or housings themselves.

An airfoil for a gas turbine engine defining a spanwise direction, a root end, a tip end, a leading edge end, and trailing edge end is provided. The airfoil includes: a body extending along the spanwise direction between the root end and the tip end, the body formed of a composite material; and a sculpted leading edge member attached to the body positioned at the leading edge end of the airfoil, the sculped leading edge member formed at least in part of a metal material and defining a non-linear patterned leading edge of the airfoil.

A system for additively manufacturing an object comprises a fiber supply that dispenses elongate fibers, a resin supply that applies a resin to the elongate fibers to create a feedstock line with the resin in a first non-rigid uncured state, a rigidizing mechanism that transforms the resin from the first non-rigid uncured state to a rigid uncured state, a delivery guide that deposits the feedstock line along a print path, a feed mechanism that feeds the feedstock line through the delivery guide, a de-rigidizing mechanism that transforms the resin from the rigid uncured state to a second non-rigid uncured state, and a curing mechanism that transforms the resin from the second non-rigid uncured state to an at least partially cured state.

A system for additively manufacturing an object comprises a source of a feedstock line, a rigidizing mechanism that receives the feedstock line from the source and transforms the resin from a first at least partially uncured state to a rigid at least partially uncured state, a delivery guide that deposits the feedstock line along a print path, a feed mechanism that feeds the feedstock line through the delivery guide, a de-rigidizing mechanism that transforms the resin from the rigid at least partially uncured state to a second at least partially uncured state, and a curing mechanism that transforms the resin from the second at least partially uncured state to an at least partially cured state.

Methods and apparatus for additive manufactures of complex parts using co-aligned continuous fibers are disclosed. Filament subunits having complex shapes are fabricated and inserted into a mold cavity. The layup is compression molded to form a complex part having high tensile strength.

A forming-material connecting device includes a cutter that cuts a forming material constituted by plural continuous fiber bundles being impregnated with a resin material and supplied in a supply direction corresponding to an extending direction of the plural continuous fiber bundles. The cutter cuts at least a portion of the plural continuous fiber bundles. The forming-material connecting device also includes a joining portion joining portions of the forming material, which are cut by the cutter at a cutting point in the forming material, on a downstream and upstream side with respect to the cutting point in the supply direction by heating to join the resin materials of the portions of the forming material, or the joining portion joins a preceding forming material's trailing end portion and a leading end portion of a following forming material by heating to join resin materials of the preceding forming material and following forming material.

A forming-material connecting device includes a cutter that cuts a forming material constituted by plural continuous fiber bundles being impregnated with a resin material and supplied in a supply direction corresponding to an extending direction of the plural continuous fiber bundles. The cutter cuts at least a portion of the plural continuous fiber bundles. The forming-material connecting device also includes a joining portion joining portions of the forming material, which are cut by the cutter at a cutting point in the forming material, on a downstream and upstream side with respect to the cutting point in the supply direction by heating to join the resin materials of the portions of the forming material, or the joining portion joins a preceding forming material's trailing end portion and a leading end portion of a following forming material by heating to join resin materials of the preceding forming material and following forming material.