Rohr, Inc.

Patrick J Nolan

Bryan Thai

A method is provided for forming a thermoplastic structure. During this formation method, a first layer of thermoplastic material is deposited on a first thermoplastic object using a material deposition device. The first layer of thermoplastic material is tacked to the first thermoplastic object during the depositing of the first layer of thermoplastic material. The first layer of thermoplastic material is consolidated with the first thermoplastic object using a material consolidation device to provide a second thermoplastic object. A second layer of thermoplastic material is deposited on the second thermoplastic object using the material deposition device. The second layer of thermoplastic material is tacked to the second thermoplastic object during the depositing of the second layer of thermoplastic material. The second layer of thermoplastic material is consolidated with the second thermoplastic object using the material consolidation device to provide a third thermoplastic object.

Independently depositing and in situ consolidating thermoplastic material

An acoustic panel includes a front skin comprising a plurality of apertures, a back skin, and a core positioned between the front skin and the back skin. The core includes at least one primary core portion including a honeycomb structure defining a plurality of cavities extending from the front skin to the back skin. The core further includes a secondary core portion external to the at least one primary core portion and including a foam structure extending from the front skin to the back skin.

Acoustic panel and method of forming same

A system for forming a composite component includes a close mold tool defining a cavity that corresponds to a shape of the composite component and configured to receive a composite material. The system further includes a perforated release film defining a plurality of openings and configured to be positioned on a surface of the composite material within the cavity. The system further includes a breather configured to be positioned on the perforated release film, to allow a vacuum to be applied to the composite material through the breather and the plurality of openings, and to allow pressurized fluid to be applied to the perforated release film through the breather.

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Laguna Hills, CA, United States of America

Patrick J Nolan