Composite control cables and stabilizing tendons for aircraft applications and method for manufacture of same

A fiber cable manufactured by a process comprising the steps of:

• providing a fiber prepreg tow comprising a plurality of fiber filaments pre-impregnated with epoxy resin;
• providing a manufacturing tool comprising a first tooling pin and a second tooling pin;
• providing a first wedge bobbin comprising a first wedge portion and a first bobbin portion and providing a second wedge bobbin comprising a second wedge portion and a second bobbin portion;
• placing the first wedge bobbin on the first tooling pin and placing the second wedge bobbin on the second tooling pin;
• wrapping the fiber prepreg tow around the first bobbin portion of the first wedge bobbin and the second bobbin portion of the second wedge bobbin a plurality of times without twisting the fiber prepreg tow;
• forming a first split of the fiber prepreg tow at the first wedge portion of the first wedge bobbin;
• lashing the fiber prepreg tow at the first split of the fiber prepreg tow;
• removing the second wedge bobbin from the second tooling pin;
• applying a shrink tube over the fiber prepreg tow;
• re-installing the second wedge bobbin on the second tooling pin;
• forming a second split of the fiber prepreg tow at the second wedge portion of the second wedge bobbin;
• lashing the fiber prepreg tow at the second split of the fiber prepreg tow;
• tensioning the fiber prepreg tow;
• applying a shrink film over a portion of the fiber prepreg tow;
• applying a first fiber wrap at the first split;
• applying a second fiber wrap at the second split;
• and
• heating the fiber prepreg tow to consolidate and cure the fiber prepreg tow to form the fiber cable.