An FRP molded product formed by impregnating a fiber base material with a matrix resin using a flow medium, wherein the flow medium has a sheet shape and comprises fibers made of a phenoxy resin, the matrix resin is an epoxy resin, the fiber base material and the flow medium are stacked, at least part of the flow medium is hardened in a state where the part of the flow medium is integrated with the matrix resin by dissolution or adhesion, and the hardened flow medium becomes a design face.

This composite material blade, which is formed using a composite material including reinforcing fibers and resin, and which has a positive pressure surface and a negative pressure surface, is provided with a ventral part, being the part on the positive pressure surface side in a blade thickness direction, which is the direction joining the positive pressure surface and the negative pressure surface, a dorsal part, being the part on the negative pressure surface side in the blade thickness direction, and a metal shield portion which is provided on the leading edge side, being the upstream side in a flow direction in which a fluid flows, wherein: the metal shield portion includes a main body portion provided on the leading edge side, and an embedded portion which is provided on the trailing edge side, being the downstream side in the flow direction, of the main body portion, and which is provided between the ventral part and the dorsal part; and the plate thickness of the metal shield portion in the blade thickness direction decreases from the main body portion toward the embedded portion.

A method for producing a planar composite component having a core layer (B), which is arranged between and integrally bonded to two cover layers (A, A′), wherein the cover layers contain a cover-layer thermoplastic and wherein the core layer contains a core-layer thermoplastic, comprises the following steps: a) a heated stack with layer sequence A-B-A′ is provided; b) the heated stack (A-B-A′) is pressed; c) the pressed stack is cooled, whereby the planar composite component with consolidated layers integrally bonded to each other is formed. To improve the production method including the producibility of planar 3D components, it is proposed, that at least one of the cover layers (A, A′) in unconsolidated form comprises a fibrous nonwoven layer of 10 to 100 wt.-% thermoplastic fibers of the cover-layer thermo-plastic and 0 to 90 wt.-% of reinforcing fibers having an areal weight of 300 to 3,000 g/m.sup.2; the core layer (B) in unconsolidated form comprises at least one randomly-oriented-fiber nonwoven layer (D) formed from reinforcing fibers and thermoplastic fibers of the core-layer thermoplastic,
and that after the pressing the consolidated core layer(s) has/have an air pore content of <5 vol.-% and the consolidated core layer has an air pore content of 20 to 80 vol-%.

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 mold for manufacturing a turbomachine fan casing made of composite material, includes a main axis mandrel around which a fibrous preform of a fan casing is intended to be wound; a plurality of counter-mold angular sectors assembled on the outer contour of the mandrel which are intended to close the mold and to compact the fibrous preform wound on the mandrel; wherein a flat seal with a main elongation axis directed along the main axis is arranged between each angular sector, the flat seal being compressed between two adjacent angular sectors, a first angular sector including a sealing portion passing below a lower face of the flat seal while a second angular sector including a sealing portion passing above an upper face of the flat seal.

A method for manufacturing a quadrangular shell having five faces and non-developable trihedral connectors between the faces. Plies having continuous fibers are cut to cover the five faces of the shell outside of the trihedral connector zones. Four connector components consolidated in the shape of the trihedral connectors are obtained. Each of the components includes an integration zone between the plies. Plies are positioned and laid up. The four consolidated components are inserted in the trihedral connection zones by inserting the integration zones between two plies to form an assembly obtain a preform. The preform is placed in a tool and the consolidation of the stack of fibrous plies is performed by subjecting the assembly to a predetermined pressure/temperature cycle.

An FRP material has a circular arc part, and a member fixed to the circular arc part. The FRP forming system has a portion-pressing device, a member positioning mechanism, and a transport device configured to form the FRP material as a single body of a circular arc-shaped FRP part. The FRP material may comprise a single layer prepreg or a plurality of prepregs that have been layered. The portion-pressing device has upper and lower molds sandwiching a portion of the FRP material in a radial direction orthogonal to the circular arc part, and compresses intermittently a portion of the FRP part. The member positioning mechanism locates the position of the member relatively to the upper or lower mold. The transport device moves the portion of the FRP material that is compressed by the portion-pressing device. The portion-pressing and the transport are repeated to form the FRP part.

An embodiment system for molding a plurality of plastic composite material panels to be assembled on a vehicle body includes a coextrusion unit configured to manufacture a multi-layered sheet in which a plurality of resin layers are laminated, a thermoforming unit configured to manufacture a forming sheet having a plurality of panel forming portions partitioned by a forming connection portion by thermoforming the multi-layered sheet, a reinforcing source spraying unit configured to spray a reinforcing source in which a fiber material and a polyurethane compound are mixed toward a preset region on the forming sheet, and a press-molding unit configured to press-mold the forming sheet applied with the reinforcing source to manufacture a composite material panel sheet in which a reinforcing layer is formed on the forming sheet.

A composite forming apparatus includes an end effector and a forming feature that is coupled to the end effector. The end effector moves the forming feature relative to a forming tool to form a composite ply over a forming surface of the forming tool or over previously formed composite material on the forming surface of the forming tool. The composite forming apparatus further includes a positioning member engaged with the forming feature. The engagement between the positioning member and the forming feature facilitates a position between the forming feature and the composite ply to promote uniform application of compaction force over the forming surface of the forming tool.

A method for forming a composite part includes positioning a composite ply over a forming surface of a forming tool, moving a forming feature into engagement with the composite ply to yield a formed ply, and, after the moving, securing the formed ply relative to the forming tool.