Airbus Operations Gmbh

Airbus UK Limited

Jago Pridie

Simon Astwood

John Jacobs

Matthew Hocking

A method of molding a charge () during the manufacture of a composite part. The method comprises: placing the charge and a diaphragm () on a male tool, the charge having a first part () which is positioned above a top of the male tool () and a second part () which projects to one side of the maletool; and progressively deforming the second part of the charge against a side of the male tool by applying a pressure difference across the diaphragm and stretching the diaphragm over the male tool as the pressure difference is applied. The diaphragm has a tensile modulus in the plane of the diaphragm which is greater than 5 MPa. Optionally a support membrane may be positioned on a opposite sides of the charge. In the case where a support membrane is used, then the diaphragm has a stiffness in the planeof the diaphragm which is higher than the stiffness of the support membrane in the plane of the support membrane.

Method of moulding a charge

A method of manufacturing two or more composite parts, the method comprising: assembling the composite parts on a mandrel by laying a series of layers of bands of composite material onto the mandrel with a placement machine,&#x2014;rotating the mandrel as the bands are laid onto the mandrel; attaching two or more debulk frames () to the mandrel between opposed edges of the composite parts after the composite parts have been assembled; wrapping the mandrel, debulk frames () and composite parts in a debulk bag; heating the composite parts,&#x2014;forming a vacuum between the mandrel and the debulk bag so that the debulk bag is sucked into voids between the debulk frames and the heated composite parts and progressively presses against the heated composite parts whereby excess material is squeezed by the debulk bag towards their opposed edges; and removing the debulk bag and the composite parts from the mandrel.

Method of manufacturing composite parts

The surface of a moulding tool, for receiving a first aircraft component, for example a spar, is shaped to correspond to the surface of a second aircraft component, for example a wing skin. A gap is defined between the tool and the first component. Resin is drawn into the gap by a suction pump. The resin fills the gap and cures to forma shim. The first and second components, which are in the form of composite material structures, are then joined together without any significant voids being formed therebetween.

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Bristol, United Kingdom

Jago Pridie