A method of producing a cascade array and a cascade array is provided. The method includes: forming a plurality of strongbacks from a first thermoplastic material; forming a plurality of comb subassemblies, each said comb subassembly including one of the plurality of strongbacks and a plurality of vanes comprising a second thermoplastic material extending outwardly from the respective one of the plurality strongbacks; and attaching the plurality of comb subassemblies into a unitary structure to produce the cascade array.

A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

A method for manufacturing a wind turbine blade is provided, including the steps of: a) arranging a fiber lay-up on a mandrel tool, the mandrel tool including a frame and, as seen in cross-section, at least two mandrel portions connected to the frame, and wherein at least a portion of the fiber lay-up is supported by an outer surface of the at least two mandrel portions, b) reducing a cross-section size of the mandrel tool by retracting at least one of the mandrel portions towards the frame, c) arranging the mandrel tool inside adjacent blade sections, d) increasing the cross-section size of the mandrel tool by extending at least one of the mandrel portions away from the frame, and e) infusing at least a portion of the fiber lay-up with a resin and curing the resin to obtain a cured joining portion joining the blade sections inside.

Compression mold assembly for forming a preform of a cascade includes first and second die elements and an axis of alignment. Line of removal of a formed preform is positioned perpendicular to a plane perpendicular to the axis of alignment. First die portion includes first curved surface forming interior surface of first strong back and second die portion includes first curved surface forming interior surface of a second strong back of a cell of a formed preform. Second die portion includes second curved surface forming an interior surface of a first vane on forward side of the cell of the formed preform and first die portion further includes first wall member which extends along line of removal and a second wall member which extends angularly from first wall portion forming an interior surface of a second vane positioned on an aft side of the cell.

A mandrel for a molding process includes a first portion and a second portion that form a mandrel having a channel between the first and second portions. At least one locking pin is configured to urge the first and second portions away from each other to establish a gap in response to inserting the locking pin into the channel along a respective end of the mandrel. A molding apparatus and method of forming a matrix composite component are also disclosed.

A device and a process for manufacturing a composite part, the device comprising four molding mandrels that can be arranged in a mold arrangement in which they form a mold for the composite part, as well as a locking mandrel configured to lock the molding mandrels in the mold arrangement and to be extracted from between the molding mandrels to release the molding mandrels from their mold arrangement. The locking mandrel extends from one longitudinal end of the molding mandrels to another opposite longitudinal end of the molding mandrels.

An example mandrel for processing a part is described including an inner core having a material with first thermal properties, and an outer layer surrounding the inner core. The outer layer includes a material with second thermal properties different than the first thermal properties to enable uniform pressure distribution within the mandrel. An example method for fabricating a composite part is described including placing a base composite layer into a cavity of a tooling surface, inserting a mandrel into the cavity, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing the base composite layer and the skin such that during curing a pressure due to thermal expansion of one of the inner core and the outer layer is distributed by the other, and removing the mandrel from the cavity of the tooling surface following the curing.

A method for producing a hollow composite structure, such as a spar beam for a wind turbine blade, includes placing a membrane within a mold tool, the membrane being permeable to air and impermeable to resin. A mandrel is placed within the mold tool, the mandrel enclosed in an air tight layer that includes a vent. Fiber reinforcement material is placed around the mandrel within the mold tool and the membrane is sealed at least partly around the fiber reinforcement material and mandrel. The mold tool is closed with the vent line from the mandrel extending through the sealed membrane to outside of the mold tool. A vacuum is drawn in the mold tool while the mandrel is vented to outside of the mold tool, and while the vacuum is being drawn, resin is infused into the mold tool around the mandrel such that the resin is drawn towards the membrane.

A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.

An additively manufactured mandrel is disclosed, including a plurality of separable segments arranged to form a main body having a first end and a second end, each separable segment connected to adjacent segments. A first plug connected to the first end, and a second plug connected to the second end of the main body are configured to support the main body during a composite curing process.