A tool for making contoured composite hat stringers allows control of stringer wrinkling. The tool includes a set of first openings that allow the tool to flex during contouring of the stringer, and a set of second openings into which portions of the composite charge may strain during the contouring.

A method for manufacturing an integrated hull by using 3D structure type fiber clothes and 3D vacuum infusion process includes: sequentially stacking at least one first fiber cloth, at least one core material and at least one second fiber cloth on a mold; deploying structural materials on the second fiber cloth; stacking the third fiber clothes to cover the structure materials and a part of the second fiber cloth, whereby the first fiber cloth, the core material, the second fiber cloth and the third fiber clothes are formed to a lamination; determining a pipe arrangement of vacuum pipes and first and second resin pipes; deploying a vacuum bag on the lamination and covering the first and second resin pipes and the vacuum pipe; executing the 3D vacuum infusion process; curing the resin; and executing a mold release process to complete an integrated hull.

A method for manufacturing a composite includes providing a first template including a cutout for a first layer of the composite, disposing the first layer in the cutout, and disposing a tablet, provided with an adhesive, on the first layer such that the first layer adheres to the tablet. Next, the tablet is removed, together with the first layer adhered thereto, from the cutout, and an adhesive is applied to a side of the first layer facing away from the tablet. A second template is provided that includes a cutout for a second layer of the composite, and then the second layer is disposed in the cutout. The tablet, together with the first layer adhered thereto, is disposed on the second layer disposed in the cutout of the second template, and the tablet is removed, together with the composite produced from the first and second layers, from the second template.

A caul for debulking a composite part broadly includes opposing first and second surfaces, a plurality of through-holes, and a coating. The first surface may have a curvature complementary to a shape of the composite part. The through-holes pass through the caul from the first surface to the second surface. The coating may be a chemically inert material to ensure the caul does not affect the composite part. The caul is configured to be positioned against the composite part for debulking. The caul may be made out of silicone rubber or any other suitable material and may be reusable.

A production method of a composite material includes placing a fiber base material on a mold. The fiber base material includes a first fiber base material portion and a second fiber base material portion. The method further includes disposing a mold release member in part of a region where the first fiber base material portion and the second fiber base material portion are in contact with each other, and curing a resin with which the first fiber base material portion and the second fiber base material portion are impregnated, so as to mold the composite material.

Systems and methods for drape forming a charge of composite material are disclosed herein. The systems include a forming mandrel, a charge support structure, a flexible and resilient forming membrane, a base, and a vacuum source. The charge support structure includes a flexible and resilient charge support membrane, a membrane suspension device, and a release structure. The release structure operatively couples the charge support membrane to the membrane suspension device when a tension on a peripheral region of the charge support membrane is less than a threshold tension and releases the charge support membrane from the membrane suspension device when the tension is greater than the threshold tension. Alternatively, and in place of the charge support structure, the systems include a means for supporting the charge of composite material. The methods include methods of drape forming a charge of composite material.

An aircraft body section comprises a first layer of composite material, a first group of conductive traces, a second layer of composite material, and a first group of conductive connectors. The first layer of composite material has an upper surface and a lower surface, with the lower surface forming an exterior surface of a body of the aircraft. The first group of conductive traces are formed on the upper surface of the first layer of composite material. The second layer of composite material is positioned on the first layer of composite material and has an upper surface and a lower surface, with the upper surface forming an interior surface of a body of the aircraft. The first group of conductive connectors is formed on the upper surface of the second layer of composite material and is configured to provide electrical connection from external conductors to the conductive traces.

A molding system and methods of forming a structure are presented. A molding system is configured to form a composite structure. The molding system comprises a first tool comprising a first vacuum groove, a first trough having a first edge configured to form a first bend of the composite structure, and a first molding surface; and a second tool comprising a second vacuum groove, a second trough having a second edge configured to form a second bend of the composite structure, and a second molding surface.

There is disclosed bagging apparatus (20) for bagging a pre-form (12) for a composite component on a tool (10), the apparatus (20) comprising: a bag dispenser (22) having a store (28) for a tubular vacuum bag (30); and a bag guide (36). In use, a length of tubular vacuum bag material (30) can be drawn from the store (28) radially outwardly over the bag guide (36) and over the tool (10) to form a tube around the pre-form. There is also disclosed a method of bagging a pre-form (12) for a composite component on a tool using the bagging apparatus (20).

A method of constructing a cured composite assembly includes positioning a composite assembly within a bonding tool, wherein the composite assembly comprises an uncured composite spar and a skin and performing a curing cycle on the composite assembly to simultaneously cure the uncured composite spar and bond the skin to the cured composite spar.