The invention concerns a fiber application machine comprising a system for moving a fiber application head, fiber storing means, and fiber conveying means from said storing means to the application head, and at least one tension limiting system (109), arranged between the fiber storing means and the application head, including at least two mutually parallel cylinders (91, 191), whereon a plurality of fibers are capable of being urged to be partly wound, and driving means (192, 193) for rotating said cylinders, substantially at the same speed, said driving means being automatically controlled by a control unit of the machine, such that the peripheral speeds of the cylinders are higher than the moving speed of the fibers at the application roll.

Fiber application machine

A stiffened skin panel (150) of an aircraft that includes an aircraft skin panel of composite material and a composite stringer (300) consolidated with the aircraft skin panel. The stringer has a pair of stringer sides (304), each extending from a stringer top (302) to a stringer leg (308). The stringer sides may each extend through a wide radius, smooth continuous curve to a stringer leg. The wide radius, smooth continuous curve may be proximate the base of the stringer side in a region where the stringer side transitions to the stringer leg.

Shaped composite stringers and methods of making

A mandrel for manufacturing a unitary seamless section of an aircraft fuselage comprises a thin lay-up mandrel element disposed onto the outer shell surface of an inner mandrel shell, forming a mandrel with a substantially continuous lay-up surface. A unitary pre-cured section of an aircraft fuselage is formed by laying up a plurality of resin impregnated skin fibers onto the mandrel's lay-up surface while the mandrel rotates.

One-piece inner shell for full barrel composite fuselage

A method and apparatus for a composite stringer. A method is used for manufacturing a hollow composite stringer. Foam is formed with a mandrel installed into the foam. A composite material and the foam is laid up onto a tool in a form of a stringer. The composite material and the foam in the form of the stringer is cured to form a cured stringer. The mandrel from the foam is removed to form the hollow composite stringer.

Foam stiffened hollow composite stringer

Embodiments of integral composite panels and joints for composite structures are described In one implementation, an integrated panel (104) spanning substantially the entire wingspan of an aircraft, includes at least a center portion (110) and a pair of outwardly projecting wing portions (106, 108). The portions may include a skin formed from successive layers or plies of composite material which overlap and offset at the joint between respective sections creating a pad-up area to carry loads between the portions. In a particular implementation, the skin is laid over one or more structural stringers (112) which are transitioned into the joints (116, 118) between sections such as by tapering of the thickness and/or stiffness of the stringer.

Composite wing-body joint

A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Single piece co-cure composite wing

A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Method of assembling a single piece co-cured structure

Process for forming a single piece co-cure composite wing

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Single piece co-cure composite wing

Method of assembling a single piece co-cured structure

Process for forming a single piece co-cure composite wing