Spirit Aerosystems, Inc.

Timothy Dean King

Robert Alexander Coleman

Steven Fillmore Hanson

Leonard Lloyd Baca

A system and method for forming a hollow, complex, monolithic composite part. Composite material may be placed around the mandrel, then an internal impermeable membrane may be placed into and/or through tunnels formed in the mandrel. Next, an external impermeable membrane may be placed around the composite material and sealed against itself and the internal impermeable membrane such that the mandrel and the composite material are both contained in an airtight manner between the internal and external impermeable membranes. Air may then be removed from within the sealed impermeable membranes, compressing the impermeable membranes against the mandrel and/or the composite material. The consolidated composite material may be hardened to form the composite part. Finally, the impermeable membrane may be removed from around the hollow composite part and from within the mandrel, followed by removal of the mandrel from within the composite part by breaking it up into smaller pieces.

Method and system for forming a complex monolithic thermoset part

An apparatus and method for tensioning material () over a mold (), such as a cure tool, comprises a tensioning fork () consisting of two substantially parallel tapered legs () between which material () is disposed. A tensioning fork () is positioned at a first side edge () and proximate a first end edge () of the material (). A first leg () of the tensioning fork () is disposed under the material (), and a second leg () of the tensioning fork () is disposed over the material (). When force is applied to the second leg (), it pivots about the first leg () along the length of the legs, remaining parallel to the first leg (), thereby pressing a portion of the material () against the mold ().

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Wichita, KS, United States of America

Timothy Dean King