Method and tool for manufacturing a quadrangular shell made of composite material

A method for manufacturing a quadrangular shell comprising five faces with flanged edges and non-developable trihedral couplings between the faces comprising:

• i. cutting plies comprising continuous fibers, the continuous fibers extending from a free edge to another free edge of the quadrangular shell, the plies comprising cut-outs so as to not cover trihedral coupling zones;
• ii. obtaining four consolidated coupling parts with a shape of the non-developable trihedral couplings, each consolidated coupling part comprising an integration zone for insertion thereof between the plies;
• iii. positioning and laying up the plies obtained in the step i);
• iv. inserting the four consolidated coupling parts into the trihedral coupling zones by inserting the integration zones between two plies to form an assembly to obtain a preform;
• and
• v. placing the preform in a tool and carrying out consolidation of lamination of fibrous plies by subjecting an assembly obtained in the step iv) to a predetermined pressure and temperature cycle.