The Boeing Company

David A Pook

Andrew K Glynn

Peter J Lockett

Steve Georgiadis

Max Marley Osborne

Martin Alexander Szarski

Samuel J Meure

Manning James Scarfe

Lauren A Burns

Ronnie K Ligeti

Andrew Glynn

A method and apparatus for manufacturing a filler for a composite structure. The apparatus may comprise a filler. The filler may comprise a fiber matrix that is uniform in all directions. The fiber matrix may comprise a first plurality of discontinuous filaments and a second plurality of discontinuous filaments. Each filament of the first plurality of discontinuous filaments may be comprised of a stiffening material. Each filament of the second plurality of discontinuous filaments may be comprised of a binding material. Discontinuous filaments of both the first plurality of discontinuous filaments and the second plurality of discontinuous filaments may be randomly oriented and entangled with each other.

Noodle comprised of a matrix of discontinuous filaments

A method of manufacturing a composite panel for an air vehicle having a predetermined size and shape. The method includes forming a frame including an outer mold line surface and at least one edge extending from the outer mold line surface. The outer mold line surface includes an OML inner surface. The edge includes an edge inner surface and an edge outer surface opposite the edge inner surface. The OML inner surface and the edge inner surface define a cavity. The method also includes positioning a plurality of uncured plies within the cavity. The OML inner surface and the edge inner surface support the uncured plies during a curing process. The method further includes curing the uncured plies using the curing process. A post-cure size and shape of the cured plies and the frame corresponds to the predetermined size and shape without trimming any of the cured plies.

System and method for a composite panel

A composite truss structure may have a first facesheet, a second facesheet, and a plurality of truss elements joined with the first facesheet and the second facesheet at nodes to form a one-piece structure. The composite truss structure may be formed by a method comprising preparing a dry fabric mold by: 1) placing a first dry fabric layer on a tool, 2) placing a first layer of fabric-loaded mandrels on the first dry fabric layer, 3) placing a second layer of the fabric-loaded mandrels on the first layer of fabric-loaded mandrels, and 4) placing a second dry fabric layer over the fabric-loaded mandrels. The method may further comprise infusing the dry fabric mold with a resin, and curing the resin to provide the nonflexible composite truss structure.

Manufacture of a resin infused one-piece composite truss structure

A system for manufacturing a composite structure includes a tool with a surface for supporting component elements of the composite structure. The surface is divided into a multi-dimensional array of thermal zones for in-process control of the temperature of a component element (e.g. resin) of the composite structure. The sensors sense a characteristic of the component element and provide sensor data, which is applied to a machine-learning algorithm configured to generate control data to achieve a defined quality goal. A controller then independently controls the thermal zones to locally heat, cool or maintain the temperature of the component element according to the control data to advance the component element or composite structure to the defined quality goal. This may be performed over a plurality of instances during which the machine-learning algorithm learns to increase advancement of the component element or composite structure to the defined quality goal.

Composite manufacturing with a multi-dimensional array of independently-controllable thermal zones

Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts. The method allows for a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish. The component may be placed in direct contact with a tool, and the caul sheet may be placed in direct contact with the component thereby eliminating the necessity for consumables between these items.

Method of manufacturing resin infused composite parts using a perforated caul sheet

Resin infused composite parts are fabricated using a caul sheet having perforations therein for optimizing the flow of resin through the parts and allowing a simplified tooling and consumable arrangement for complex parts while achieving a smooth, aerodynamic caul-side or bag-side finish.

Resin infusion of composite parts using a perforated caul sheet

A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure.

Composite structures having integrated stiffeners with smooth runouts and method of making the same

A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.

Flexible truss frame and method of making the same

A unitized composite structure comprises a composite member having at least one integrally formed composite stiffener. At least one end of the stiffener includes a runout forming a substantially smooth transition between the stiffener and the composite structure. The stiffener and runout may comprise a crown, side walls, and base cap. The transition in the runout may include a width of the crown increasing, a height of the side walls decreasing, and the base cap splaying outwardly.

A composite structure is made by placing a stiffener preform and a composite structure reinforcement on a tool. The preform and the reinforcement are vacuum bagged processed and co-infused with a thermoset resin to form a stiffened, unitized structure.

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Malvern East, Australia

David A Pook