A composite structure manufacturing method comprising: a lamination step in which a plurality of fiber-reinforced resin sheets are laminated to form a plate-shaped laminate; a pressing deformation step in which a third roller or similar, which rolls along a plate surface of the laminate, is used to press the plate surface of the laminate, thereby forming a recessed section or a protruding section in a prescribed section of the laminate; a short direction deformation step in which, after the pressing deformation step, the laminate is deformed in the short direction to make the long direction cross-section into a prescribed shape; and a long direction deformation step in which, after the pressing deformation step, the laminate is deformed in the long direction to make the short direction cross-section into a prescribed shape.

A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

A system for manufacturing a part includes a mold having a contoured forming surface. The system also includes at least one tension strap, configured to attach to a consolidated laminate sheet, and a heating assembly, positioned relative to the mold and configured to supply heat to the consolidated laminate sheet, when attached to the at least one tension strap, to form a heated consolidated laminate sheet. The system additionally includes a strap retraction mechanism, configured to retract the at least one tension strap, when attached to the consolidated laminate sheet, to force the heated consolidated laminate sheet against the contoured forming surface of the mold. The heating assembly includes a flexible heating element configured to flex to conform to a shape of the heated consolidated laminate sheet as the heated consolidated laminate sheet is forced against the contoured forming surface of the mold.

A system for manufacturing a part includes a mold having a contoured forming surface. The system also includes at least one tension strap, configured to attach to a consolidated laminate sheet, and a heating assembly, positioned relative to the mold and configured to supply heat to the consolidated laminate sheet, when attached to the at least one tension strap, to form a heated consolidated laminate sheet. The system additionally includes a strap retraction mechanism, configured to retract the at least one tension strap, when attached to the consolidated laminate sheet, to force the heated consolidated laminate sheet against the contoured forming surface of the mold. The heating assembly includes a flexible heating element configured to flex to conform to a shape of the heated consolidated laminate sheet as the heated consolidated laminate sheet is forced against the contoured forming surface of the mold.

A method of offset load testing a tubular composite specimen with two pairs of aligned holes and having at least one defect, the method comprising: providing a testing apparatus having a pair of arms including a fixed arm and a mobile arm; securing the pair of arms using a fastener assembly in each of the two pairs of aligned holes; and moving the mobile arm to impart an offset load force to the tubular specimen. One aspect includes a method of offset load testing comprising: providing a testing apparatus having a pair of arms including a fixed arm and a mobile arm; providing a tubular composite specimen with a top portion and a bottom portion; securing the pair of arms to the top and bottom portions of the tubular composite specimen; and moving the mobile arm to impart an offset load force to the tubular composite specimen.

A method of offset load testing a tubular composite specimen with two pairs of aligned holes and having at least one defect, the method comprising: providing a testing apparatus having a pair of arms including a fixed arm and a mobile arm; securing the pair of arms using a fastener assembly in each of the two pairs of aligned holes; and moving the mobile arm to impart an offset load force to the tubular specimen. One aspect includes a method of offset load testing comprising: providing a testing apparatus having a pair of arms including a fixed arm and a mobile arm; providing a tubular composite specimen with a top portion and a bottom portion; securing the pair of arms to the top and bottom portions of the tubular composite specimen; and moving the mobile arm to impart an offset load force to the tubular composite specimen.

An intensifier mechanism for forming stacked material includes a support, a first body coupled to the support, and a second body having a main portion, a pivoting portion, and a joint. The main portion is coupled to the support and the joint movably couples the main portion to the pivoting portion. The joint allows the pivoting portion to pivot in relation to the main portion when the membrane moves towards the bottom wall.

An intensifier mechanism for forming stacked material includes a support, a first body coupled to the support, and a second body having a main portion, a pivoting portion, and a joint. The main portion is coupled to the support and the joint movably couples the main portion to the pivoting portion. The joint allows the pivoting portion to pivot in relation to the main portion when the membrane moves towards the bottom wall.

A molding process for the production of a cover wall section for a cover in which the cover wall section has at least one multi-layer fabric that has a reinforcement and, at least on one side, preferably on both sides, a polymer coating, has the following process steps: Provision of at least one multi-layer fabric; draping of the at least one fabric over a molding surface of a mold and stretching of the at least one fabric across the molding surface by at least one tension element; and curing of the at least one fabric and/or the at least one tension element in such a way that the cover wall section is fixed in its shape.

A molding process for the production of a cover wall section for a cover in which the cover wall section has at least one multi-layer fabric that has a reinforcement and, at least on one side, preferably on both sides, a polymer coating, has the following process steps: Provision of at least one multi-layer fabric; draping of the at least one fabric over a molding surface of a mold and stretching of the at least one fabric across the molding surface by at least one tension element; and curing of the at least one fabric and/or the at least one tension element in such a way that the cover wall section is fixed in its shape.