A method for producing a three-dimensional preform from reinforcing fibers for producing a component from a fiber-reinforced plastic comprises the steps of introducing at least one layer of fibers having a binder into a draping mold, forming the at least one layer of fibers by at least one forming element which is displaceable along the draping mold, applying an airtight film to the at least one layer of fibers during or directly after the forming, creating a negative pressure in the intermediate space between the airtight film and the draping mold, activating the binder and removing the negative pressure after curing of the binder.

A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

A molding system and methods of forming a structure are presented. The molding system is configured to sequentially form features of a structure. The molding system comprises a first tool comprising a number of features configured to completely form a first set of radii of a structure and a number of partial forming features configured to partially form a second set of radii of the structure, and a second tool comprising a number of completion features configured to complete shaping of the second set of radii.

A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

A resin barrier device for connection in a vacuum line, for use in resin infusion during composite manufacture, includes a housing having an inlet port for connection to a resin source and an outlet port for connection to a vacuum source. A flow path extends between the inlet and outlet ports. A gas-permeable membrane is disposed across the flow path to prevent resin from flowing to the vacuum pump. A gasket supports the membrane and is adapted to prevent resin leakage. A method of infusing a preform with a resin also is provided.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A system for fabricating a composite structure includes a ply carrier including a ply support surface configured to support at least one composite ply. The system includes a carrier transfer device configured to convey the ply carrier. The system includes a lamination system configured to selectively apply the at least one composite ply to the ply support surface of the ply carrier. The system includes a transfer system configured to remove the ply carrier from the carrier transfer device and to apply the at least one composite ply to at least a portion of a forming surface of a forming tool. The system includes a forming system configured to form the at least one composite ply over the at least a portion of the forming surface of the forming tool.