Systems and methods are provided for composite part fabrication. One embodiment is a method that includes placing a laminate onto a base of a mandrel between side walls of the mandrel, placing edge dams between the side walls and the laminate that each abut the laminate and abut one of the side walls, each edge dam having a Coefficient of Thermal Expansion (CTE) greater than a CTE of the mandrel, the CTE of the mandrel being greater than a CTE of the laminate, heating the laminate, edge dams, and mandrel, and during the heating, thermally expanding the edge dams an amount that corresponds with a difference in thermal expansion between the laminate and the mandrel.

A device (10) comprising a carrier material (14) and a matrix material (12) deposited onto the carrier material in a pattern that leaves a predetermined amount of space (18) between each deposition of matrix material.

In one embodiment, a method may comprise heating a composite material into a viscous form, wherein the composite material comprises a thermoplastic and a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is randomly arranged within the thermoplastic. The method may further comprise extruding a plurality of strands of the composite material, wherein extruding the plurality of strands causes the plurality of reinforcement fibers within each strand to align. The method may further comprise arranging the plurality of strands of the composite material to form an assembly fixture, wherein the assembly fixture comprises an anisotropic thermal expansion property, and wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the assembly fixture.

A part assembly including a curing shield and a method for secondarily bonding two parts of the part assembly utilizing the curing shield. The method for secondary bonding includes fixing a base of a clip of a curing shield to a first surface of a first part. The curing shield includes a pad fixed to the clip. The clip has the base and a spine fixed to and extending away from the base and terminating at a distal end. The pad extends along at least a portion of a length of the spine between the base and the distal end. The method also includes applying adhesive along a faying surface of one of the first part and a second part. The second part is assembled to the first part along the faying surface so that the distal end of the clip extends toward the second surface and the curing shield defines a pocket adjacent the faying surface at least partly enclosed by the pad.

A part assembly including a curing shield and a method for secondarily bonding two parts of the part assembly utilizing the curing shield. The method for secondary bonding includes fixing a base of a clip of a curing shield to a first surface of a first part. The curing shield includes a pad fixed to the clip. The clip has the base and a spine fixed to and extending away from the base and terminating at a distal end. The pad extends along at least a portion of a length of the spine between the base and the distal end. The method also includes applying adhesive along a faying surface of one of the first part and a second part. The second part is assembled to the first part along the faying surface so that the distal end of the clip extends toward the second surface and the curing shield defines a pocket adjacent the faying surface at least partly enclosed by the pad.

A method for manufacturing a metal-clad laminate sheet containing (i) a thermoplastic liquid crystal polymer film comprising a thermoplastic polymer, and (ii) a metal foil bonded to at least one surface of the thermoplastic liquid crystal polymer film, the thermoplastic polymer being capable of forming an optically anisotropic molten phase, and the method containing: forming a laminate sheet having the thermoplastic liquid crystal polymer film and the metal foil bonded together; and heat treating the laminate sheet, wherein the heat treatment satisfies conditions (1) and (2): (1) wheat treatment temperature ranges between 1 C. inclusive and 50 C. exclusive higher than a melting point of the thermoplastic liquid crystal polymer film, and (2) a time for the heat treatment ranges from one second to 10 minutes.

A method for manufacturing a multilayer circuit board containing a single-sided metal-clad laminate sheet and a substrate laminated together, the single-sided metal-clad laminate sheet containing a thermoplastic liquid crystal polymer film and a metal foil bonded to a surface of the thermoplastic liquid crystal polymer film, and the method containing: forming a laminate sheet having the thermoplastic liquid crystal polymer film and the metal foil bonded together; and heat treating the laminate sheet, wherein the heat treatment satisfies conditions (1) and (2) to manufacture the single-sided metal-clad laminate sheet: (1) a heat treatment temperature ranges between 1 C. inclusive and 50 C. exclusive higher than a melting point of the thermoplastic liquid crystal polymer film, and (2) a time for the heat treatment ranges from one second to 10 minutes.

Systems and methods are provided for composite part fabrication. One embodiment is a method that includes placing a laminate onto a base of a mandrel between side walls of the mandrel, placing edge dams between the side walls and the laminate that each abut the laminate and abut one of the side walls, each edge dam having a Coefficient of Thermal Expansion (CTE) greater than a CTE of the mandrel, the CTE of the mandrel being greater than a CTE of the laminate, heating the laminate, edge dams, and mandrel, and during the heating, thermally expanding the edge dams an amount that corresponds with a difference in thermal expansion between the laminate and the mandrel.

Provided is a method for forming a co-cured composite article. The method includes: providing a bag carrier; providing a vacuum bag, wherein the vacuum bag at least partially surrounds the bag carrier; providing an outer skin, wherein the outer skin at least partially surrounds the vacuum bag; forming a space between the bag carrier and the the outer skin; and providing a filler between the outer skin and the bag carrier.

In one embodiment, a method may comprise heating a composite material into a viscous form, wherein the composite material comprises a thermoplastic and a plurality of reinforcement fibers, wherein the plurality of reinforcement fibers is randomly arranged within the thermoplastic. The method may further comprise extruding a plurality of strands of the composite material, wherein extruding the plurality of strands causes the plurality of reinforcement fibers within each strand to align. The method may further comprise arranging the plurality of strands of the composite material to form an assembly fixture, wherein the assembly fixture comprises an anisotropic thermal expansion property, and wherein the anisotropic thermal expansion property is based on an orientation of the plurality of reinforcement fibers within the assembly fixture.