A method of manufacturing curved composite structural elements can include fabricating a web ply in a flat curve over a removable substrate and laying up the ply on a curved web surface of a manufacturing tool. The method also can include laying up a diagonal ply with fibers oriented at +/−45° from the centerline of the web surface. The method further can include cutting a unidirectional composite tape into segments and laying up the tape segments to form a cross ply with a fiber orientation normal to the centerline of the web surface. One or both edges of the diagonal and cross plies may be folded over one or two sides of the manufacturing tool to form one or two flange surfaces. Additionally, a cap ply can be laid up on one or both flange surfaces using composite tape. The structural element layup can then be inspected and any excess composite material can be trimmed away.

Method of manufacturing curved composite structural elements

A three-dimensional printer uses leveling screws with tactile feedback to assist a user in properly orienting a build platform within a working volume.

Build platform leveling with tactile feedback

A polymer-based composite sandwich includes a reinforced core bonded between a pair of composite facesheets. The core includes a truss formed by groups of composite pins held in place by a layer of structural foam. The pins in the groups are radially arranged around nodes. The ends of the pins are splayed and sandwiched between the foam layer and the facesheets.

Composite structure having reinforced core and method of making same

Anti-icing methods and aerodynamic structures having laminated resistive heaters for de-icing are described. Several of the inventive aspects utilize laminated resistive heaters comprising a carbon nanotube layer and/or capacitors to store and supply electricity. The invention also includes methods of making aerodynamic structures having de-icing or anti-icing functionality.

Anti-icing, de-icing, and heating configuration, integration, and power methods for aircraft, aerodynamic, and complex surfaces

The invention regards a de-icing/anti-icing system comprising at least two conductive structures (3', 3") embedded in an article (2), which includes an outer surface (5) being designed as an aerodynamic surface, at least one of the conductive structures (3'f 3") is arranged adjacent the outer surface (5), a control unit (39) is adapted to control the energy supply to the conductive structures (3', 3") for generating heat to the outer surface (5) One conductive structure (31) comprises a first conductive nano structure (19'), the conductive structure's (3') conductive property differs from the conductive property of the other conductive structure (3") comprising a second conductive nano structure (19").

Multifunctional de-icing/anti-icing system

The invention relates to a method of manufacturing an integral article comprising a fiber-reinforced composite material. An inner tool body (12) of a cellular plastic material is provided, onto which an airtight sheet (14) of a flexible material is applied so as to fully encompass and seal the tool body (12). A plurality of layers (16) of fiber-reinforced composite material are then applied onto the outer surface of the airtight sheet (14), and an airtight vacuum bag (18) is in turn applied onto the outer layer of the composite material (16). The vacuum bag (18) is evacuated and the layers (16) of composite material compressed. The composite material is heat treated so as to cure the same. The vacuum bag (18) is then removed from the thus formed article. To form a hollow integral tank, the formed article is provided with a hole (22), and a solvent is poured therein to dissolve the cellular plastic material. The dissolved material is then drained through the hole (22), and the airtight sheet (14) is possibly removed theretrough.

A method of manufacturing an integral article comprising a fiber-reinforced composite material, and a tool assembly for making the same

The present invention relates to a composite radius filler for use in an aircraft structure (2), which comprises structural composite parts (7) assembled together to form the aircraft structure (2). The composite radius filler (3) is arranged between rounded sections (5', 5") of the structural composite parts (7) for filling a gap (4) formed between the structural composite parts (7). The composite radius filler (3) is made structural by a nanostructure (23) arranged within the composite radius filler (3) for the reinforcement of the interface between the radius filler (3) and the structural composite part (7). The invention also relates to a method for producing an aircraft structure comprising said nano-reinforced radius filler.

Nano-reinforced radius filler for an aircraft structure and a method of producing an aircraft structure comprising such filler

A method and device for shaping of an article of composite material. The method includes arranging a blank of composite material on a top surface of a forming tool. A portion of the blank is arranged to protrude outside the top surface of the tool. At least one support is arranged in contact with an underside of the protruding portion of the blank. An air-tight foil is arranged over the arrangement. The air-tight foil is forced towards the blank. The support is lowered until the blank is shaped over the tool. The support is stopped and/or removed. The device includes a tool including a top surface and side surface for shaping at least one blank of composite material into an article having a predetermined profile; and a air-tight foil. The device further includes at least one support arranged to be in supporting contact with the underside of the protruding part of the blank.

Method and device for shaping of composite material

The present invention regards an aircraft structure comprising structural composite parts (5) assembled together to form said aircraft structure (3); said aircraft structure (3) further comprises a bonding interlayer material provided (17) to bond said structural composite parts (5) to each other. The bonding interlayer material (17) comprises a nanostructure enhanced material (20, 21). The invention also regards a method of producing an aircraft structure of assembled structural composite parts (5), being cured or semi-cured before said assembly.

An aircraft structure with structural parts connected by nanostructure and a method for making said aircraft structure

The present invention relates to a stiffening element (1) and a method for manufacturing of a stiffening element (1) of composite material, which stiffening element (1) is provided for attachment to a curved shell surface (9). A substantial flat blank (29) of composite material comprising a first (13) and a second (15) essentially parallel elongated edge is provided for forming in the web (3) of the stiffening element (1) at least one rounded bulge (19) having a conical form tapering from the first edge (13) to a first folding line (17). Thereby is achieved a curved flange (5), which first folding line (17) essentially merges with an apex of the rounded bulge (19).

Björn Weidmann

Papers

A method of manufacturing an integral article comprising a fiber-reinforced composite material, and a tool assembly for making the same

Nano-reinforced radius filler for an aircraft structure and a method of producing an aircraft structure comprising such filler

Method and device for shaping of composite material

An aircraft structure with structural parts connected by nanostructure and a method for making said aircraft structure

A stiffening element and a method for manufacturing of a stiffening element