Methods of fabricating a multi-region U-shaped composite structure, the methods comprising the steps of laying up a first composite material on a first tool piece to form a first sidewall, laying up the second composite material on a second tool piece tool to form a second sidewall, re-orienting the first tool piece and the second tool piece to a consolidation orientation, laying up the third composite material to form a nose wall, and overlapping at least a portion of the third composite material with at least a portion of the first composite material and at least a portion of the second composite material.

A turbomachine blade includes a blading made of composite material with a fibrous reinforcement densified by a matrix and a metal leading edge formed by a metal foil, the foil having an intrados fin and an extrados fin which extend respectively over intrados and extrados faces of the blading by conforming to an airfoil of the blade, wherein the blade also includes at least one unidirectional fabric ply made of composite material on the leading edge between the blading and the metal foil, each unidirectional fabric ply extending at least partially over the intrados and extrados faces of the blading.

Composite structures and methods of forming composite structures are provided. A composite structure as disclosed herein incorporates one or more composite structure components, such as composite panels and composite inserts. A composite panel is formed from one or more sheets of fiber reinforced thermoplastic material. Composite inserts can include one or more composite blocks or braided sleeves. A composite block can be formed as a stacked or molded structure from trimmings or waste produced during the formation of the composite structures. A braided sleeve can include a seamless, woven sleeve formed of reinforcing fibers and thermoplastic threads. In a completed composite structure, composite inserts are at least partially disposed within a volume defined by surfaces of composite panels. The various composite structures and inserts can be given a final shape and can be fused to one another in a molding and fusing step.

A method for manufacturing a composite material part having a cellular structure that includes at least one cell delimited by walls. The method includes supplying at least a first core, providing a web of a first fibrous reinforcement comprising a plurality of long discontinuous fibers randomly distributed in a plane, and producing at least one strip of the first fibrous reinforcement. The method further includes producing a second fibrous reinforcement in the shape of a sock, inserting the first core into the sock, draping the strip around the sock containing the first core, placing the sock containing the first core and the wrapped strip in a mold, and thermocompression.

A forming device, system, and method for continuous forming of a semi-finished fiber product. The semi-finished fiber product is supported flatly from a first side and is at least locally restricted in its freedom of movement, for example pressed on and/or guided, on another side opposite the first side. The further restriction occurs in relation to a guiding area at at least one constant location or region past which the semi-finished fiber product is guided. Shaping tools and guiding areas defined thereby are used for support, and hold-down devices and their contact surfaces are used for further restriction. The further restriction is carried out transversely to a feed motion direction of the semi-finished fiber product through the forming device. The further restriction and the flat guidance serve to reduce formation of undulations and folds.

Methods for producing an annular casing for an aircraft turbine engine are provided. The annular casing includes an annular body made from a composite material based on a first resin, and a fire-resistant outer layer which covers an external annular surface of the body and which is made from a composite material based on a self-extinguishing second resin. The method includes preparing a strip of a glass fabric preimpregnated with said second resin, this strip including woven fibres oriented in directions that are perpendicular to one another and inclined by an angle of approximately 45° with respect to the axis of elongation of the strip, and applying the strip to the external surface of the body so as to cover the entirety of this surface in a single pass of the strip around the body.

The invention relates to a three dimensional shaped article having an outer and inner surface, the outer surface comprising at least one fabric (100) of polyethylene fibers having a tensile strength of at least 1.5 GPa, the fabric is impregnated with an acrylic based thermoplastic material. The three dimensional shaped article may further comprise monolayers with unidirectional aligned fibers. The three dimensionally shaped article has an improved surface appearance which would therefore need little or no post treatment and has good adhesion to coatings and paints.

A fiber structure body includes a several fiber layers stacked in a stacking direction and has a multi-axial orientation that includes axial-force directional yarns, orthogonal directional yarns, and intersecting yarns. The fiber structure body includes a flat plate portion and a bend portion that is bent to the flat plate portion and includes a surface intersecting with a surface of the flat plate portion. The axial-force directional yarns are made of continuous fiber of reinforced fiber. Of yarns that form the bend portion and are other than the axial-force directional yarns, yarns that form at least one axis of the bend portion are provided by spun yarns made of discontinuous fiber.

A structural web having a fabric material element 20 that has been stitched or embroidered with a reinforcing fiber 24, the fabric material element 20 defining a peripheral region 28a, 30a, and the reinforcing fiber 24 extending onto the peripheral region 28a,30a, the fabric material element 20 and reinforcing fiber 24 being bent to take on a non-planar form with the peripheral region 28a, 30a angled to a main plane of the element 20 to define an engagement face for cooperation with another component 12, 14, and upon which at least part of the reinforcing fiber 24 is located.

A method of manufacturing a rim includes placing at least one braided sleeve on a core dimensioned to define a shape of an internal wall of the rim. The method includes inserting the braided sleeves placed on the core, inside a mold that is dimensioned to define a shape of an external wall shape of the rim. The method further includes injecting a resin inside the mold to contact the mold and impregnate the sleeves and other layers with resin. The method also includes curing the resin to form the internal and external walls of the rim and obtain a cured rim having the core connected thereto. The method further includes removing the cured rim and core from the mold and melting the core to get it out of the rim.