Apparatus and Methods for Forming Composite Components

The method of any preceding claim, wherein the elastomeric bladder is vacuum integral, optionally maintaining vacuum integrity to a maximum loss of 10mbar or less over a defined time period, optionally a maximum loss of 5mbar or less over the defined period.

The method of any preceding claim, wherein the method comprises a closed mould manufacturing method, with the composite part being formed between at least two mould tools, optionally wherein the two mould tools are closed and sealed for vacuum integrity at a temperature in a range of ambient temperature (e.g. 20° C.) to 205° C.

The method of any preceding claim, wherein the tooling assembly comprises a plurality of relatively rigid tools or mandrels, the elastomeric bladder being arranged intermediate the relatively rigid tools or mandrels so as to mitigate compounding of multiple tolerances associated with the respective plurality of relatively rigid tools or mandrels, optionally wherein a compound tolerance associated with a dimension defining a portion of the torque box within the mould is a compounding of tolerances of both the relatively rigid tools or mandrels and the elastomeric bladder/s.

The method of any preceding claim, wherein the manufacture is performed out of autoclave.

The method of any preceding claim, wherein curing is performed at a curing temperature, the curing temperature being in a range of 50° C. to 205° C.

The method of any preceding claim, wherein the method comprises forming the composite part without any re-forming, such as post-curing re-forming (e.g. by heating and moulding).

The method of any preceding claim, wherein the method comprises manufacturing a plurality of composite parts;

• and wherein the method comprises sequentially manufacturing the plurality of composite parts with a same elastomeric bladder for at least 50 cycles, optionally 120 cycles or more.

The method of any preceding claim, wherein the method comprises inserting the elastomeric bladder into the mould after the preform has been loaded, optionally wherein at least one of:

• the method comprises inserting the elastomeric bladder into the preform in the mould longitudinally, such that the elastomeric bladder is installed within the preform;
• and/or
• the method comprises wrapping the elastomeric bladder in peel ply and/or flow mesh for insertion.

The method of any preceding claim, wherein the method comprises at least one of:

• forming at least one spar, the elastomeric bladder being associated with a spar-forming mandrel;
• optionally wherein the method comprises installing a spar preform and the elastomeric bladder after the initial preform of the skin has been loaded or wherein the method comprises installing a spar preform and the flexible elastomeric in the preform of the skin before loading the preform of the skin on the tooling.

The method of any preceding claim, wherein the method comprises forming dry carbon fibre into at least two preforms, the two preforms defining an upper skin preform and a lower skin preform.

The method of any preceding claim, wherein the mandrel comprises a solid carbon mandrel, wherein the directionally laminated and/or machined to provide a differential coefficient of thermal expansion (“CTE”), the differential CTE providing a relatively higher CTE in a first direction relative to a second direction, optionally wherein at least one of:

• the differential CTE provides a consolidation pressure on the torque box during curing;
• the mandrel is below nominal size at a temperature due to the differential CTE, optionally wherein the temperature is ambient temperature and optionally an elevated temperature, such as an infusion temperature.

The method of any preceding claim, wherein the method comprises directly heating at least a portion of the tooling assembly, such as directly heating a carbon fibre mandrel or the flexible bladder, optionally wherein the method comprises induction heating and/or wherein the method comprises infra-red heating.

A method of manufacturing a preform for a composite part, the method comprising stretch-forming a preform with bagging whereby a consolidation force is progressively applied from a first portion of the preform towards a second or further portion(s) of the preform which is distally located from the first portion.

A composite part manufacturing tooling assembly, the tooling assembly comprising a mould;

• a mandrel and a elastomeric bladder;
• wherein the elastomeric bladder and the mandrel are incorporated in the tooling assembly for vacuum sealing.

The tooling assembly of claim 50, wherein the differential CTE provides a consolidation pressure on the composite part during curing.