Described are methods and systems for repair of composite components without the use of vacuum bagging. The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

A method for repairing a part made of composite material includes producing a recessed section by removing the composite material at a damaged area, producing grooves extending on the two faces of the part from edges of the recessed section, producing orifices in the part opening out into the grooves, tree-dimensional weaving of a filling part fiber preforms including a central section having a shape corresponding to the shape of the recessed section and fiber bundles extending from the central section, placing the filling preforms respectively on either face of the part with the fiber bundles in the grooves on the faces of the part and in the orifices such that the fiber bundles open out into the grooves present on the opposite face of the part, impregnating the filling fiber preforms with a precursor resin of a matrix, transforming the resin into a matrix to obtain a filling part.

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.

A method is provided involving a fairing for a turbine engine. During this method, a detail is provided. The detail includes a carrier and an exterior layer bonded to the carrier. The carrier is configured from or otherwise includes fiber-reinforced composite material. The exterior layer is configured from or otherwise includes polymer material. The detail is arranged with the fairing. The fairing includes an exterior side and an edge. The detail covers and extends along at least a portion of the exterior side. The detail wraps at least partially around the edge. The carrier and at least a first overhang portion of the exterior layer are bonded to the fairing.

Matching pieces for broken structures, kits comprising matching pieces for broken structures, methods for generating 3-D models for matching pieces, methods for fabricating matching pieces, systems for generating 3-D models for matching pieces, and systems for fabricating matching pieces are disclosed.

Matching pieces for broken structures, kits comprising matching pieces for broken structures, methods for generating 3-D models for matching pieces, methods for fabricating matching pieces, systems for generating 3-D models for matching pieces, and systems for fabricating matching pieces are disclosed.

A repair system that includes a handheld device comprising a first extruder tip having an interior passageway extending between an inlet and a tip outlet, wherein the inlet is configured to receive a solid thermoplastic material and the tip outlet is configured to dispense a fluidic thermoplastic material; a nozzle surrounding the first extruder tip to form an annulus between an interior surface of the nozzle and an exterior surface of the first extruder tip; and a heater that is configured to heat the interior passageway of the first extruder tip such that the solid thermoplastic material becomes the fluidic thermoplastic material. In some embodiments, the repair system also includes a gas source in fluid communication with the annulus such that a skirt-shaped curtain of gas extends from the annulus and in a direction towards the tip outlet of the extruder tip.

An apparatus is provided for analysis of a repair for a structure by identifying component parts of the structure that have common material properties and geometric constraints, and based thereon determining a generic repair component for the component parts that also have the common material properties and the geometric constraints. A set of loads are extracted from a loads model of the undamaged structure and redistributed in a loads redistribution model at a damaged or defective portion of the component part. The set of redistributed loads indicate loading incurred by the generic repair component under an external load. The apparatus then uses the redistributed loads to perform an analysis to determine a margin of safety of the generic repair component and, in instances in which the margin of safety is positive, outputs the material properties and geometric constraints of the generic repair component to a fabrication system for production thereof.

A method for recovering vinyl window frames. The method of recovering vinyl window frames includes identifying damages in an existing vinyl frame having a plurality of planes, wherein the damages exist in at least one plane, measuring the area of the frame to be covered, creating a template of the frame by securing pre-cut plates together with a gap between to allow for bending along the gap, such that the template can conform to the frame, marking cuts to be made to the replacement cover using the template, cutting the replacement cover to duplicate the existing frame, and applying the replacement cover over the existing vinyl frame.