Shifting is a method for manipulating unidirectional non-crimp fabrics that allows for a curved fiber path along with compound surface geometry. The bases for shifting is understanding unidirectional (UD) non-crimp-fabrics (NCFs) as a semi-flexible prismatic linkage and planning manipulations such that the array of linkages can conform to the surface geometry and path plan within allowable manufacturing tolerances. This has applications in structural composite components such as the current trailing edge prefabricated unidirectional components for wind turbine blades, and for future wind turbine blade designs including a curve-linear spar cap.

A method of manufacturing a fibre-composite article is described, wherein a layer of fibre material is applied from a layup head to a mould along a layup path. The angle at which the fibre material is dispensed from the layup head is rotated relative to the angle of orientation of the layup path, to minimise the effects of gravity on the alignment of the fibre layer in the mould. The fibre-composite article is preferably a section of a blade for a wind turbine.

A method for manufacturing a structural element for a fuselage of an aircraft. To improve the manufacture of structural elements, a method includes laying up textile material members on a mandrel to form a plurality of structural element preforms that are space apart along an extended direction of the mandrel. The structural element preforms form closed loops and are subsequently cured to obtain annular structural elements. The annular structural elements are used as basic building blocks for stiffening panel members or are directly used as structural frame elements reinforcing cut-outs in a fuselage for windows and/or doors.

A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.

The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis.

Disclosed herein are devices and methods for manufacturing uncured, near-net shape plies. Such devices include: a plurality of spools, each dispensing a dry tow; optionally, a plurality of spreaders to spread the dry tows; optionally, a means to combine the dry tows into a plurality of tapes or bundles; a plurality of feeders, each carrying a tow, tape or bundle, and adapted to maintain the tows, tapes or bundles in a parallel arrangement; a cutting apparatus adapted to independently cut each individual tow, tape or bundle to a pre-determined length; optionally, a conveyor adapted to transport the cut tows, tapes or bundles away from the cutting apparatus; an in-line resin infuser adapted to impregnate the dry tows, tapes or bundles with resin material; and a receiver for the cut tows, tapes or bundles, wherein the cut tows, tapes or bundles are impregnated and configured in the form of a near-net shape ply.

A molding machine places strips of a tape material side by side and molds the tape material into a molded shape having a web portion and a flange portion, the tape material including a continuous fiber bundle extending in a longitudinal direction. The molding machine includes spreading unit able to increase a width of the tape material by spreading the tape material, and a laying roller that places the tape material which has passed through the spreading unit onto a surface of a molding tool. The spreading unit continuously changes the width of the tape material to avoid generation of a gap between adjacent strips of the tape material, the adjacent strips being adjacent to each other when the tape material is placed on the surface of the molding tool, and the laying roller places the strips of the tape material side by side in a plurality of rows.

A method and system for determining the quality and configuration of a structure that is constructed from a thermoformable material, such as a thermoplastic or thermoset material, and in particular thermoplastic composite tapes, where heat is applied to cure the thermoformable material. The quality of the build is monitored during the construction of the structure by determining the differential heat flux in the material as it cools from its elevated temperature. The system and method also may determine the location of defects in a structure being constructed so that remedial measures may be taken or production operations halted to address the defect. A transient thermal effect is applied to the structure being monitored, such as the thermoformable material being applied, which may be implemented from the applied heating of the thermoformable construction application process or additional heating.

A composite fuel tank includes a tank-shell and a tank-liner, located within the tank-shell. The tank-shell is formed from a composite layup that is placed, consolidated, and cured on a bladder. The bladder forms the tank-liner after formation of the tank-shell.