A method for manufacturing a composite part by laying up courses of composite tape using an automated tape layup (ATL) machine onto a conductive flexible facesheet laid flat on a flat surface, and then transferring the facesheet with the composite material thereon to a curved tooling surface for attachment of substructures and curing into the composite part. The method may also include applying insulation below the facesheet and above the composite material, then heating the conductive facesheet to cure the composite tape and fuse the composite tape to the substructures without heating the tooling surface or any other items used to compress and cure the composite material into the composite part. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to a plurality of conductive wires attached at opposing ends to the facesheet.

A method for producing a fiber reinforced plastic can suppress with which wrinkling or bridging in a convex surface or a concave surface having a large curvature at the same time even if the fiber reinforced plastic has a complicated three-dimensional shape. Such methods for producing a fiber reinforced plastic may involve shaping a prepreg sheet in which continuous fibers are impregnated with a resin material into a three-dimensional shape to produce a fiber reinforced plastic (a); wherein at least a portion of the continuous fibers in an area (X) of the prepreg sheet corresponding to an area (X′) in which the fiber reinforced plastic (a) is shear-deformed is bent in an in-plane direction in advance.

A tape sectioning system, comprising a tape web feed path for feeding a web of fiber reinforced tape, a quality inspection system arranged along the web feed path that inspects the quality of the web of tape, and a sectioner that sections off longitudinal tape sections from the web of tape, wherein the sectioner is arranged to vary the length of the tape sections that are sectioned off from the web of tape based on the outcome of the quality inspection.

A dry tape material for fiber placement includes a plurality of reinforcing fiber strands that satisfy (i) to (iii): (i) the reinforcing fiber strand has thicknesses T1 and T3 at both ends in a width direction of a section of the reinforcing fiber strand, and both T1 and T3 are 50 to 200% relative to a thickness T2 at a central portion of the reinforcing fiber strand, (ii) the reinforcing fiber strand has a number of filaments N and a width W that satisfy a relationship of 4.8<N/W<12, and (iii) the reinforcing fiber strand has a form kept by a first resin material having a glass transition temperature Tg or a melting point Tm of 40° C. to 200° C., the first resin material being heat-meltable, wherein the plurality of reinforcing fiber strands are bound and integrated with each other by a second resin material.

A thermoplastic composite structure is produced by consolidating and forming a composite preform to a desired shape. The preform comprises plies of a high melt temperature thermoplastic prepreg that are tacked together by a low melt temperature thermoplastic adhering the plies together in fixed registration.

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 scrap collection assembly for a tape lamination head that applies a plurality of composite tape segments includes a crack-off assembly with a scrap crack-off redirect roller configured to engage one or more composite tape segments and one or more scrap portions; and a secondary crack-off roller configured to engage one or more composite tape segments and one or more scrap portions; a pivot that connects the crack-off assembly to the tape lamination head, wherein the secondary crack-off roller selectively moves about the pivot to change a direction of composite tape movement.

A thermoplastic product includes a fabric-based reinforcing sheet and a polymerized thermoplastic material. The fabric-based reinforcing sheet is wound about a mandrel to form a plurality of layers having a cross-sectional shape that corresponds to the mandrel. The fabric-based reinforcing sheet includes a plurality of fiber bundles, which may have a bidirectional orientation or configuration. A polymerized thermoplastic material is disposed within each layer of the fabric-based reinforcing sheet. The polymerized thermoplastic material bonds each layer of the fabric-based reinforcing sheet to an adjacent layer.

A method of manufacturing an arc-shaped fiber composite component includes forming a preform with a planar fiber layer arrangement formed along an arc and having an outer edge assigned to a convex outer side of the arc. The outer edge is formed with gaps extending into the arrangement in such a manner that a contour of the gaps is formed at least in sections near a target contour of a respective recess to be provided in the component. The preform is formed such that a first region of the arrangement, adjacent to the outer edge and extending substantially in the direction of the arc, is bent or angled relative to a second region of the arrangement, adjacent to the first region remote from the outer side of the arc. The gaps that the preform has prior to reshaping merge into recesses of the formed preform and remain open.

A method for integrating a backing-structure assembly in a structure of an aircraft or spacecraft is described. In this case, a plurality of individual elements is joined to form the backing-structure assembly. The individual elements for the backing-structure assembly and a skin portion for the structure are provided. The elements are arranged on a pre-assembly device which comprises retaining devices, which are each configured to hold one of the elements so as to be adjustable with respect to the position and/or location thereof. Some or all of the elements are connected to the skin portion. In the method, by adjusting the retaining devices for tolerance compensation, gaps between joint regions of the elements and the skin portion are eliminated or adjusted.