Composite material repair

Abstract

The invention relates to composite material repair. A composite structure and method are presented. A method of repairing a composite material is presented. A fiber mixture is forced through the composite structure and into voids of the composite structure, the fiber mixture comprising a binder and a plurality of electromagnetically manipulatable fibers. An electromagnetic field is applied to the fiber mixture within the voids of the composite structure. The binder of the fiber mixture is cured to form a composite repair having structural properties.

Description

Technical Field

[0001] The present disclosure relates generally to composite material manufacturing and, more particularly, to the repair of composite material structures. Background Art

[0002] A “knock-down factor” is often applied to composite repairs. The knock-down factor is the calculated reduction in strength or other mechanical properties resulting from the repair. The knock-down factor limits the suitability of composite parts.

[0003] Different types of repairs have different “knock-down factors.” The cost and complexity of a composite repair is related to the “knock-down factor.” The more difficult, complex, and generally more expensive the composite repair procedure, the lower the “knock-down factor.” Composite repairs with reduced “knock-down factors” result in significantly increased repair complexity, repair analysis, and cost.

[0004] Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues.For example, it would be desirable to provide a new composite material repair method with reduced complexity and reduced "knockdown factor". Summary of the invention

[0005] Examples of the present disclosure provide a method for performing a composite repair. A fiber mixture is forced through a composite structure and into a void in the composite structure. The fiber mixture includes a binder and a plurality of electromagnetically steerable fibers. An electromagnetic field is applied to the fiber mixture within the void of the composite structure. The binder of the fiber mixture is cured to form a composite repair having structural capability.

[0006] Another example of the present disclosure provides a method for performing a composite repair. A fiber mixture is forced through at least one injection hole in a composite structure and into a void in the composite structure. The fiber mixture includes a binder and a plurality of electromagnetically steerable fibers. After the fiber mixture is introduced into the void, an electromagnetic field is applied to the fiber mixture in the void. The binder of the fiber mixture is cured to form a composite repair having structural properties.

[0007] Yet another example of the present disclosure provides a composite structure having a composite repair having structural properties. The composite structure includes a plurality of cured composite plies having voids creating separations within the plurality of cured composite plies; a plurality of injection holes connecting the voids to the exterior of the plurality of cured composite plies; and a cured resin having a plurality of electromagnetically steerable fibers within the separations, forming a composite repair, and configured to transmit forces to the composite plies in contact with the composite repair.

[0008] The features and functions can be achieved independently in various examples of the present disclosure or may be combined in yet other examples in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The novel features believed to be characteristic of the illustrative examples are set forth in the appended claims. However, the illustrative examples together with the preferred mode of use, further objects and features thereof will be best understood by reference to the following detailed description of illustrative examples of the disclosure when read in conjunction with the accompanying drawings, in which:

[0010] Figure 1 is a diagram of an aircraft according to an illustrative example;

[0011] Figure 2 is an illustration of a block diagram of a manufacturing environment according to an illustrative example;

[0012] Figure 3 is an illustration of a cross-sectional view of a void in a composite material structure according to an illustrative example;

[0013] Figure 4 is an illustration of a cross-sectional view of a composite material structure having a void and a plurality of injection holes according to an illustrative example;

[0014] Figure 5 is an illustration of a cross-sectional view of a composite structure having a composite repair according to an illustrative example;

[0015] Figure 6 is an illustration of a cross-sectional view of a composite repair according to an illustrative example;

[0016] Figure 7 is an illustration of a cross-sectional view of a void in a composite material structure according to an illustrative example;

[0017] Fig. 8A and 8B is a flow chart of a method of performing composite material repair according to an illustrative example;

[0018] Fig. 9is a flow chart of a method for composite material repair according to an illustrative example;

[0019] Fig.10 is a diagram of an aircraft manufacturing and service method in block diagram form according to an illustrative example; and

[0020] Fig.11 An illustration, in block diagram form, of an aircraft in which an illustrative example may be implemented. DETAILED DESCRIPTION

[0021] The illustrative examples take into account one or more different considerations. For example, the illustrative examples recognize and take into account that delamination is a break between layers of a composite material that causes the layers to peel away from each other. Delamination can result in voids in a composite structure. The illustrative examples take into account that voids may also be created in a composite structure in other ways during manufacturing. The illustrative examples also take into account that voids in a composite structure may be accessible from an edge of the composite structure. In some examples, the voids are contained within the composite structure and are not accessible from an edge or exterior of the composite structure.

[0022] The illustrative examples consider several traditional types of composite delamination responses. Scarf and patch composite repairs involve mechanical removal of the delamination and laying down of matching composite layers. Mechanical removal is usually performed by sanding, which produces debris. A taper ratio is used to remove the delamination and therefore also remove a large amount of "good" material.

[0023] In an inlay and patch composite repair, the patch is manufactured to match the material being removed. The removal and patch placement process is time consuming and the material costs can be quite high. If not placed correctly during the repair, the patch can be mechanically removed and replaced again.

[0024] The illustrative example considers that another traditional delamination response is the encircling process. In the encircling process, a mechanical clamping force is used to prevent the delamination from growing in size. By encircling the delamination with a fastener, a "compression zone" is created through which the delamination will have difficulty propagating. Encircling involves the introduction of additional holes and only mitigates the delamination, not repairs it.

[0025] Another illustrative example of delamination repair considered is injection repair. The standard material used for injection repair is a two-component resin that is mixed and immediately injected and then allowed to cure. Injection repair is the easiest and least expensive means of repairing delamination. Holes may be drilled to help access the delamination in the part. Adhesive is then injected into the holes to fill the delamination. The goal of the injection is to prevent the delamination from progressing further by filling the resulting “void”. In the case of a delamination that cannot be accessed, then surface preparation is not possible and the mechanical properties of the cured resin may be unknown or inconsistent.

[0026] Illustrative Example Consider that an injection repair may be considered a surface repair. An injection repair may be considered not to bear structural loads. Therefore, an injection repair may have a higher knockdown coefficient.

[0027] The illustrative examples contemplate that by improving the structural properties of an injection repair, it may be possible to prevent a significant increase in repair cost and complexity. The illustrative examples contemplate that in order to improve the structural properties of a composite repair, the mechanical properties of the repair material may be improved. The illustrative examples contemplate that if the mechanical properties of the repair are improved, subsequent "knockdown" will be reduced.

[0028] Now go to Figure 1 , depicts a diagram of an aircraft according to an illustrative example. Aircraft 100 has wing 102 and wing 104 attached to fuselage 106. Aircraft 100 includes engine 108 attached to wing 102 and engine 110 attached to wing 104.

[0029] Fuselage 106 has tail section 112 . Horizontal stabilizer 114 , horizontal stabilizer 116 , and vertical stabilizer 118 are attached to tail section 112 of fuselage 106 .

[0030] Aircraft 100 is an example of an aircraft that may have a composite part with a composite repair. Aircraft 100 is an example of an aircraft that may have a composite part repaired using the method of the illustrative example. At least one of fuselage 106, wing 102, or wing 104 may have a composite repair with a fiber mixture to provide structural performance.

[0031] Now go to Figure 2 , an illustration of a block diagram of a manufacturing environment is depicted according to an illustrative example. Composite structure 202 may be repaired in manufacturing environment 200. Composite structure 202 may be Figure 12. Composite structure 202 is a view of a portion of aircraft 100. Composite structure 202 has composite repair 204 having structural properties 206. Composite structure 202 includes a plurality of cured composite plies 208, wherein voids 210 create separations 212 within the plurality of cured composite plies 208. In some illustrative examples, composite structure 202 includes a plurality of injection holes 214 connecting voids 210 to exteriors 216 of the plurality of cured composite plies 208. Composite structure 202 further includes cured resin 218 having a plurality of electromagnetically steerable fibers 220 within separations 212, forming composite repair 204, and configured to transfer forces to the composite plies in contact with composite repair 204. In some illustrative examples, composite repair 204 is configured to transfer forces to intact composite plies in contact with composite repair 204. In some illustrative examples, composite repair 204 is configured to transfer forces to undamaged composite plies in contact with composite repair 204. In some illustrative examples, composite repair 204 transfers force via lap shear. In some illustrative examples, composite repair 204 is configured to transfer force to a surface to which it is adhered.

[0032] Void 210 is a three-dimensional space within composite structure 202. The size and edges of void 210 are not completely known.

[0033] Plurality of cured composite layups 208 includes plies of fibers reinforced by resin 240. Each ply in the plurality of cured composite layups is one of unidirectional 238 or woven 242.

[0034] Unlike conventional processes, composite repair 204 does not have a fiber orientation configured to match plurality of cured composite plies 208. Composite repair 204 includes plurality of electromagnetically steerable fibers 220 oriented in a direction that is independent of respective layup angles of plurality of cured composite plies 208. Composite repair 204 is a three-dimensional fiber reinforcement within void 210. The direction of plurality of electromagnetically steerable fibers 220, such as first direction 224 or second direction 230, is independent of the fiber angles in plurality of cured composite plies 208, which are unidirectional 238 or woven 242.

[0035] Plurality of electromagnetically steerable fibers 220 may have any desired orientation within composite repair 204. In some illustrative examples, each of plurality of electromagnetically steerable fibers 220 has approximately the same orientation. In some illustrative examples, plurality of electromagnetically steerable fibers 220 includes more than one orientation.

[0036] Plurality of electromagnetically steerable fibers 220 has any desired fiber length 232, fiber type 234, or fiber coating 236. Fiber length 232 may affect the mobility of plurality of electromagnetically steerable fibers 220 within cured resin 218 prior to curing. Fiber type 234 may affect the movement by electromagnetic fields generated by plurality of electromagnetic sources 276. In some illustrative examples, fiber coating 236 may be applied to plurality of electromagnetically steerable fibers 220 to change the material properties of plurality of electromagnetically steerable fibers 220. In some illustrative examples, fiber coating 236 may be applied to plurality of electromagnetically steerable fibers 220 to change the responsiveness of plurality of electromagnetically steerable fibers 220 to electromagnetic fields.

[0037] In some illustrative examples, plurality of electromagnetically steerable fibers 220 includes first group of fibers 222 oriented along first direction 224 relative to plurality of cured composite plies 208. In some illustrative examples, plurality of electromagnetically steerable fibers 220 includes first group of fibers 222 oriented along Z-direction 226 relative to plurality of cured composite plies 208. Z-direction 226 is substantially perpendicular to each ply in plurality of cured composite plies 208. In some illustrative examples, Z-direction 226 extends through the thickness of composite structure 202. By extending perpendicular to plurality of cured composite plies 208, first group of fibers 222 in Z-direction 226 may transfer forces between plies in plurality of cured composite plies 208.

[0038] In some illustrative examples, plurality of electromagnetically steerable fibers 220 includes first group of fibers 222 oriented along first direction 224 and second group of fibers 228 oriented along second direction 230. In some illustrative examples, first direction 224 and second direction 230 are different orientations within composite repair 204. In some illustrative examples, first group of fibers 222 and second group of fibers 228 differ from one another based on at least one of fiber length 232, fiber type, or fiber coating.

[0039] To form composite repair 204 in composite structure 202, repair 244 is performed on composite structure 202. Repair 244 includes forcing 245 fiber mixture 258 into voids 210 in composite structure 202. Fiber mixture 258 may be forced into voids 210 in any desired method. In some illustrative examples, forcing 245 in repair 244 includes one of syringe injection 246 or vacuum infusion 248. After forcing 245 fiber mixture 258 into voids 210, fiber mixture 258 is cured 286 to form composite repair 204. Fiber mixture 258 that is forced into voids 210 is cured to form composite repair 204 having cured resin 218 and plurality of electromagnetically steerable fibers 220.

[0040] In some illustrative examples, prior to syringe injection 246 or vacuum infusion 248, a plurality of injection holes 214 may be formed 250 on composite structure 202, such as by drilling, cutting, boring, etc. Formation 250 may be performed by a drill, a hole saw, a reamer, a counterbore, or any other desired tool. A plurality of injection holes 214 extend into void 210, providing communication between the exterior of composite structure 202 and void 210. In some illustrative examples, void 210 extends to edge 215 of composite structure 202 and is open to exterior 216 of composite structure 202.

[0041] Injector 254 may be used to inject fiber mixture 258 into void 210 through plurality of injection holes 214 or edge 215. In some illustrative examples, injector 254 takes the form of syringe 256. In these illustrative examples, fiber mixture 258 is present in injector 254. Fiber mixture 258 includes binder 260 and plurality of electromagnetically steerable fibers 264. In some illustrative examples, binder 260 takes the form of resin 262. In some illustrative examples, binder 260 takes the form of epoxy or any other desired type of binder.

[0042] Plurality of electromagnetically steerable fibers 264 has plurality of fiber lengths 266 and plurality of fiber types 268. Plurality of fiber types 268 includes any desired type of fiber, such as carbon fibers, carbon nanotubes, graphite fibers, boron fibers, aramid fibers, glass fibers, metal fibers, wood or other natural fibers, and / or other materials. In some illustrative examples, plurality of electromagnetically steerable fibers 264 includes fiber coating 270. In some illustrative examples, when present, fiber coating 270 aids in adhesion and / or electromagnetic sensitivity.

[0043] Multiple electromagnetically steerable fibers 264 are selected based on multiple fiber lengths 266 and quantity such that fiber mixture 258 can be applied by injection or another desired method. The number of fibers in multiple electromagnetically steerable fibers 264 in fiber mixture 258 is sufficient to provide a mechanical benefit in composite repair 204. The number of fibers in multiple electromagnetically steerable fibers 264 is low enough so that the viscosity of fiber mixture 258 is low enough to force 245 fiber mixture 258 through composite structure 202 and into voids 210. In some illustrative examples, the number of fibers in multiple electromagnetically steerable fibers 264 is low enough so that the viscosity of fiber mixture 258 is low enough to fill voids 210.

[0044] Plurality of electromagnetically steerable fibers 264 is configured to align longitudinal axes 272 of plurality of electromagnetically steerable fibers 220 with the respective electromagnetic fields when contained within the electromagnetic fields. In some illustrative examples, fiber types 234 are capable of aligning plurality of electromagnetically steerable fibers 220. In some illustrative examples, plurality of fiber types 268 are capable of aligning plurality of electromagnetically steerable fibers 220. In some illustrative examples, fiber coating 270 is capable of aligning plurality of electromagnetically steerable fibers 220.

[0045] Multiple electromagnetic sources 276 are used to orient longitudinal axes 272 of multiple electromagnetically steerable fibers 264. In some illustrative examples, multiple electromagnetic sources 276 are used to orient longitudinal axes 272 of multiple electromagnetically steerable fibers 264 before forcing 245 fiber mixture 258 into void 210. In some illustrative examples, multiple electromagnetic sources 276 are used to orient longitudinal axes 272 of multiple electromagnetically steerable fibers 264 while forcing 245 fiber mixture 258 into void 210. In some illustrative examples, multiple electromagnetic sources 276 are used to orient longitudinal axes 272 of multiple electromagnetically steerable fibers 264 while fiber mixture 258 fills void 210. In some illustrative examples, multiple electromagnetic sources 276 are used to orient longitudinal axes 272 of multiple electromagnetically steerable fibers 264 in void 210 after filling but before curing 286. In some illustrative examples, during curing 286 , number of electromagnetic sources 276 are used to orient longitudinal axes 272 of number of electromagnetically steerable fibers 264 in voids 210 .

[0046] As depicted, plurality of electromagnetic sources 276 includes first electromagnetic source 278 and second electromagnetic source 282. In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 have different orientations relative to composite structure 202 to align fibers in different directions. In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 have different intensities. In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 are configured to affect different groups in plurality of electromagnetically steerable fibers 220. In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 are configured to affect the same fibers in plurality of electromagnetically steerable fibers 220.

[0047] In some illustrative examples, first electromagnetic source 278 is configured to apply first electromagnetic field 280 to fiber mixture 258 within void 210. In some illustrative examples, first electromagnetic source 278 is configured to alternately apply first electromagnetic field 280 while forcing fiber mixture 258 into void 210. By alternating the application of first electromagnetic field 280, at least a portion of plurality of electromagnetically steerable fibers 264 moves between being aligned by first electromagnetic field 280 and being aligned by forcing 245 fiber mixture 258.

[0048] In some illustrative examples, first electromagnetic source 278 is configured to apply first electromagnetic field 280 to fiber mixture 258 within void 210 while forcing fiber mixture 258 into void 210 to apply pressure to fibers lodged in void 210. During forcing 245 into composite structure 202, plurality of electromagnetically steerable fibers 264 may be oriented to move around three-dimensional obstacles in void 210. During introduction into composite structure, plurality of electromagnetically steerable fibers 264 may be oriented to break up blockages in the flow of fiber mixture 258 in void 210. Plurality of electromagnetically steerable fibers 264 may be oriented prior to or during curing 286 to provide structural properties 206 in composite repair 204. In some illustrative examples, first electromagnetic source 278 is configured to apply first electromagnetic field 280 to fiber mixture 258 within void 210 to increase filling of void 210 by fiber mixture 258.

[0049] In some illustrative examples, second electromagnetic source 282 is configured to apply second electromagnetic field 284 to fiber mixture 258 within void 210 when forcing fiber mixture 258 into void 210. In some illustrative examples, second electromagnetic source 282 is configured to alternately apply second electromagnetic field 284 to fiber mixture 258 within void 210 when first electromagnetic field 280 is inactive to force fiber mixture 258 into void 210. In these illustrative examples, second electromagnetic field 284 has a different direction than first electromagnetic field 280. In some illustrative examples, using first electromagnetic field 280 and second electromagnetic field 284 to alternately move plurality of electromagnetically manipulable fibers 264 can increase the movement of plurality of electromagnetically manipulable fibers 264 over a single electromagnetic field in a single direction. In some illustrative examples, using first electromagnetic field 280 and second electromagnetic field 284 to alternately move plurality of electromagnetically manipulable fibers 264 can increase pressure on fibers trapped within void 210 when forcing fiber mixture 258 into void 210.

[0050] In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 are configured to align different groups of fibers. In some illustrative examples, first electromagnetic source 278 is configured to align first group of fibers 222 along first direction 224. In some illustrative examples, second electromagnetic source 282 is configured to align second group of fibers 228 along second direction 230 that is different from first direction 224.

[0051] In some illustrative examples, first electromagnetic source 278 and second electromagnetic source 282 are configured to be used during different portions of repair 244. In some illustrative examples, first electromagnetic source 278 is configured to be used during forcing 245 fiber mixture 258 into voids 210, while second electromagnetic source 282 is configured to be used during curing 286.

[0052] Figure 2 The illustration of manufacturing environment 200 is not intended to imply physical or architectural limitations on the manner in which the illustrative examples may be implemented. Other components other than the components shown or other components that replace the components shown may be used. Some components may be unnecessary. Moreover, these blocks are presented to illustrate some functional components. When implemented in the illustrative examples, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0053] For example, plurality of electromagnetically steerable fibers 220 may include only one group of fibers. In other illustrative examples, plurality of electromagnetically steerable fibers 220 may include more than two groups of fibers.

[0054] Now go to Figure 3, depicts an illustration of a cross-sectional view of a void in a composite structure according to an illustrative example. Composite structure 300 is Figure 2 300. Composite structure 300 includes a plurality of cured composite plies 302 and voids 304. Voids 304 reduce the structural performance of composite structure 300. Voids 304 create separations 306 within plurality of cured composite plies 302. Although some boundaries of voids 304 can be detected by nondestructive inspection, voids 304 have an unknown three-dimensional shape.

[0055] The illustration of void 304 is depicted for discussion purposes only and is not limiting. The size or shape of void 304 may be exaggerated relative to composite structure 300 and composite layup 302 for ease of discussion.

[0056] Now go to Figure 4 , an illustration of a cross-sectional view through a composite structure having voids and a plurality of injection holes is depicted, according to an illustrative example. In view 400, a plurality of injection holes 402 are formed in composite structure 300. In some illustrative examples, plurality of injection holes 402 are formed in composite structure 300 by drilling, cutting, or boring into composite structure 300. Plurality of injection holes 402 are formed in composite structure 300 to access voids 304. Plurality of injection holes 402 connect voids 304 to exteriors 404 of plurality of cured composite layups 302. Plurality of injection holes 402 include injection holes 406 and injection holes 408.

[0057] In some illustrative examples, multiple injection holes 402 may be used to perform a vacuum infusion procedure. In some illustrative examples, multiple injection holes 402 may be used to perform a syringe injection.

[0058] Now go to Figure 5 , an illustration of a cross-sectional view of a composite structure with a composite repair is depicted in accordance with an illustrative example. View 500 is a view of composite structure 300 with composite repair 502. Composite repair 502 is formed within separation 306.

[0059] Composite repair 502 has structural properties. Composite repair 502 includes a cured resin having a plurality of electromagnetically steerable fibers. Composite repair 502 is configured to transfer a force to a composite layup in contact with composite repair 502. In some illustrative examples, composite repair 502 is configured to transfer a force to an intact or undamaged composite layup in contact with composite repair 502. In some illustrative examples, composite repair 502 is configured to transfer a force to a surface to which it is adhered.

[0060] The orientation of the plurality of electromagnetically steerable fibers in a composite repair may be controlled by the plurality of electromagnetic sources 504. The location of the plurality of electromagnetic sources 504, the timing of the use of the plurality of electromagnetic sources 504, and the mode of use of the plurality of electromagnetic sources 504 may be used to orient the plurality of electromagnetically steerable fibers.

[0061] A plurality of electromagnetic sources 504 are depicted relative to composite structure 300. Plurality of electromagnetic sources 504 may be used to control the orientation of a plurality of electromagnetically steerable fibers in composite repair 502 during at least one of prior to introduction into voids 304, during introduction into voids 304, during filling of voids 304, prior to curing of composite repair 504, or during curing of composite repair 504. Plurality of electromagnetic sources 504 include electromagnetic sources at different angles relative to composite repair 502. By having the electromagnetic sources at different angles relative to composite structure 300, plurality of electromagnetic sources 504 may orient the plurality of electromagnetically steerable fibers at different angles.

[0062] As depicted, plurality of electromagnetic sources 504 includes electromagnetic source 506, electromagnetic source 508, and electromagnetic source 510. Electromagnetic source 506 is positioned above the top surface of composite structure 300. Electromagnetic source 508 is positioned at an angle relative to the top surface of composite structure 300. Electromagnetic source 510 is approximately perpendicular to electromagnetic source 506. Electromagnetic source 510 is positioned along a side of composite structure 300.

[0063] Electromagnetic source 506 is positioned to orient electromagnetically steerable fibers in a direction perpendicular to the plurality of cured composite plies 302. The perpendicular direction relative to the plurality of cured composite plies 302 may be referred to as being positioned in the Z-direction. Electromagnetic source 510 is positioned to orient electromagnetically steerable fibers in a direction parallel to the plurality of cured composite plies 302. Electromagnetic source 508 is positioned to orient electromagnetically steerable fibers at an angle relative to the plurality of cured composite plies 302.

[0064] Fiber orientation within composite repair 502 may be set using multiple electromagnetic sources 504. Since the shape of void 304 is unknown, electromagnetically steerable fibers may get caught at the edge of void 304. Since the shape of void 304 is unknown, electromagnetically steerable fibers may clump. In some illustrative examples, multiple electromagnetic sources 504 may be used to create back pressure behind the fiber clumps. In some illustrative examples, multiple electromagnetic sources 504 may be used to move electromagnetically steerable fibers to move fibers away from the edge of the void. In some illustrative examples, multiple electromagnetic sources 504 may be used to improve filling of void 304.

[0065] In some illustrative examples, selectively activating many of plurality of electromagnetic sources 504 may be used to enhance filling of voids 304. In some illustrative examples, selectively activating a single electromagnetic source of plurality of electromagnetic sources 504 may be used to enhance filling of voids 304. In some illustrative examples, electromagnetic source 510 may be used to orient fibers to flow within voids 304.

[0066] In some illustrative examples, the strength of plurality of electromagnetic sources 504 may be the same for each. In some illustrative examples, the strength of at least one electromagnetic source in plurality of electromagnetic sources 504 is different from the strength of the remaining electromagnetic sources in plurality of electromagnetic sources 504 .

[0067] Plurality of electromagnetic sources 504 is a non-limiting example of the number and location of electromagnetic sources. There may be any desired number, size, and location of electromagnetic sources in plurality of electromagnetic sources 504.

[0068] Now go to Figure 6 , depicts an illustration of a cross-sectional view of a composite repair according to an illustrative example. View 600 is Figure 5 5. Composite repair 502 of FIG. 500 includes cured resin 604 having a plurality of electromagnetically steerable fibers 602. In this illustrative example, plurality of electromagnetically steerable fibers 602 include a first group of fibers 606 and a second group of fibers 608. As depicted, first group of fibers 606 and second group of fibers 608 have two different directions. As depicted, first group of fibers 606 and second group of fibers 608 have two different directions based on two different lengths of fibers. First group of fibers 606 have a shorter length than second group of fibers 608. First group of fibers 606 are oriented in the Z-direction relative to plurality of cured composite layups 302 of composite structure 300.

[0069] In some illustrative examples, one of the plurality of electromagnetic sources 504 is used to orient second group of fibers 608. In some illustrative examples, second group of fibers 608 is oriented by the flow of cured resin 604 prior to curing. In some illustrative examples, first group of fibers 606 is oriented using one of the plurality of electromagnetic sources 504, such as electromagnetic source 506. In some illustrative examples, due to the size of first group of fibers 606, first group of fibers 606 is able to move within the resin as the resin cures. In some illustrative examples, due to the size of second group of fibers 608, second group of fibers 608 is restricted from moving during curing. In some illustrative examples, first group of fibers 606 is selectively oriented in the Z-direction based on at least one of a difference in fiber type, fiber length, or fiber coating between first group of fibers 606 and second group of fibers 608.

[0070] Figure 2-6is just one illustrative example of a composite structure having a void and a composite repair. The composite structure can have any desired size, shape, and layup, including any number or fiber angles of composite plies. The composite repair can be introduced in any desired manner. In some illustrative examples, a composite repair can be formed by introducing a fiber mixture including a resin and a plurality of electromagnetically steerable fibers 602 through more than one injection hole. The composite repair can include any desired orientation of the plurality of electromagnetically steerable fibers.

[0071] Now go to Figure 7 , depicts an illustration of a cross-sectional view of a void in a composite structure according to an illustrative example. Composite structure 700 is Figure 2 700 is a physical implementation of composite structure 202. Composite structure 700 includes a plurality of cured composite plies 702 and voids 704. Voids 704 reduce the structural performance of composite structure 700. Voids 704 create separations 706 within plurality of cured composite plies 702. In this illustrative example, voids 704 are in communication with edge 708 of composite structure 700.

[0072] In some illustrative examples, the composite material repair may be performed on void 704 from edge 708. In some illustrative examples, the composite material repair may be performed on void 704 without introducing injection holes into composite material structure 700.

[0073] Now go to Fig. 8A and 8B , depicts a flow chart of a method for performing composite material repair according to an illustrative example. The method 800 may be performed to Figure 1 The method 800 may be performed to produce a composite material repair in a composite material part of an aircraft 100. Figure 2 Composite material repair 204. Method 800 can be Figure 3-6 The method 800 may be performed to form a composite material structure 300. Figure 5-6 The method 800 can be performed on the composite structure 700 to form a composite repair.

[0074] Method 800 forces a fiber mixture through a composite structure and into a void of the composite structure, the fiber mixture including a binder and a plurality of electromagnetically steerable fibers (operation 802). Method 800 applies an electromagnetic field to the fiber mixture within the void of the composite structure (operation 804). Method 800 cures the binder of the fiber mixture to form a composite repair having structural properties (operation 806). Method 800 then terminates.

[0075] In some illustrative examples, method 800 forms a plurality of injection holes in the composite structure to reach a void in the composite structure (operation 808). In some illustrative examples, forcing the fiber mixture into the void includes forcing the fiber mixture through at least one hole in the plurality of injection holes and into the void (operation 808).

[0076] In some illustrative examples, forcing the fiber mixture into the void includes vacuum infusing the fiber mixture into the void (operation 810). Vacuum infusion may include applying a vacuum to the void within the composite structure. The vacuum applied to the void is used to force the fiber mixture through at least one of the injection holes or an edge of the composite structure.

[0077] In some illustrative examples, forcing the fiber mixture into the void includes injecting the fiber mixture into the void (operation 812). Injecting the fiber mixture into the void may include at least one of injecting the fiber mixture into a plurality of injection holes or injecting from an edge of the composite structure. The fiber mixture may be injected using any desired injection device. In some illustrative examples, the injection device may include a syringe.

[0078] In some illustrative examples, applying the electromagnetic field to the fiber mixture within the void includes alternating the application of the electromagnetic field while forcing the fiber mixture into the void (operation 814). In some illustrative examples, alternating the application of the electromagnetic field while forcing the fiber mixture into the void increases filling of the void. In some illustrative examples, alternating the application of the electromagnetic field while forcing the fiber mixture into the void creates pressure behind a mass of fibers. In some illustrative examples, alternating the application of the electromagnetic field while forcing the fiber mixture into the void reduces sticking of fibers at edges of the void.

[0079] In some illustrative examples, applying the electromagnetic field to the fiber mixture within the void includes applying pressure to the fibers retained within the void while forcing the fiber mixture into the void (operation 816). In some illustrative examples, applying a single electromagnetic field alternately applies pressure to the fibers retained within the void. In some illustrative examples, applying multiple electromagnetic fields with different directions alternately applies pressure to the fibers retained within the void.

[0080] In some illustrative examples, applying the electromagnetic field to the fiber mixture within the voids includes filling the voids with the increased fiber mixture (operation 818). In some illustrative examples, applying the electromagnetic field aligns the fibers with the flow of the fiber mixture to increase the filling of the voids. In some illustrative examples, applying the electromagnetic field reduces agglomeration of the fibers, thereby increasing the filling of the voids. In some illustrative examples, applying the electromagnetic field creates movement in the resin to increase the filling of the voids.

[0081] In some illustrative examples, applying the electromagnetic field to the fiber mixture includes alternating activation of the electromagnetic field while forcing the fiber mixture into the void (operation 820). In some illustrative examples, method 800 alternately applies a second electromagnetic field within the void while forcing the fiber mixture into the void and when the electromagnetic field is inactive, the second electromagnetic field having a different direction than the electromagnetic field (operation 822).

[0082] In some illustrative examples, applying the electromagnetic field to the fiber mixture within the void includes aligning at least a portion of the plurality of electromagnetically steerable fibers in the void along a Z direction (operation 824).

[0083] In some illustrative examples, applying the electromagnetic field to the fiber mixture within the void includes orienting a first group of fibers in the plurality of electromagnetically steerable fibers in a first direction (operation 826). In some illustrative examples, method 800 orients a second group of fibers in the plurality of electromagnetically steerable fibers in a second direction (operation 828).

[0084] In some illustrative examples, a binder curing of the fiber mixture is performed while a first group of fibers in the plurality of electromagnetically steerable fibers are in a first orientation and a second group of fibers in the plurality of electromagnetically steerable fibers are in a second orientation (operation 830). In some illustrative examples, the first group of fibers and the second group of fibers are different from each other based on at least one of fiber length, fiber type, or fiber coating (operation 832). By being different from each other based on at least one of fiber length, fiber type, or fiber coating, the first group of fibers and the second group of fibers can be subjected to different effects of the electromagnetic field. In some illustrative examples, the difference in at least one of fiber length, fiber type, or fiber coating can allow for selective alignment of one of the first group of fibers or the second group of fibers.

[0085] Now go to Fig. 9 , depicts a flow chart of a method for performing composite material repair according to an illustrative example. The method 900 may be performed to Figure 1 The method 900 may be performed to form a composite material repair in a component of the aircraft 100. Figure 2 Composite material repair 204. Method 900 can be performed to repair Figure 3-6 The voids 304 in the composite material structure 300 are shown.

[0086] Method 900 forces a fiber mixture through at least one injection hole in a composite structure and into a void in the composite structure, the fiber mixture including a binder and a plurality of electromagnetically steerable fibers (operation 902). After introducing the fiber mixture into the void, method 900 applies an electromagnetic field to the fiber mixture within the void (operation 904). Method 900 cures the binder of the fiber mixture to form a composite repair having structural properties (operation 906). Method 900 then terminates.

[0087] In some illustrative examples, forcing the fiber mixture through at least one hole includes injecting the fiber mixture into the gap using an injector (operation 908). In some illustrative examples, the injector includes a pneumatic or mechanical injector. In some illustrative examples, the injector is a vacuum injector. In some illustrative examples, the injector is a syringe. In some illustrative examples, method 900 electromagnetically manipulates the electromagnetically manipulable fibers in the injector before injecting the fiber mixture into the gap (operation 910). In some illustrative examples, an electromagnetic field is applied to the electromagnetically manipulable fibers in the injector to align the electromagnetically manipulable fibers in the desired flow direction from the injector. In some illustrative examples, an electromagnetic field is applied to the electromagnetically manipulable fibers in the injector to align the electromagnetically manipulable fibers parallel to the nozzle of the injector. In some illustrative examples, the electromagnetically manipulable fibers are oriented before being introduced into the gap to help reduce the viscosity of the fiber mixture.

[0088] In some illustrative examples, applying the electromagnetic field includes applying the electromagnetic field during curing (operation 912). In some illustrative examples, the electromagnetic field is applied during curing to maintain a desired orientation of at least one set of electromagnetically steerable fibers. In some illustrative examples, the electromagnetic field is applied during curing to align the electromagnetically steerable fibers in a Z-direction.

[0089] In some illustrative examples, applying the electromagnetic field includes orienting a first group of fibers in the plurality of electromagnetically steerable fibers in a first direction (operation 914). In some illustrative examples, method 900 applies a second electromagnetic field to the fiber mixture to orient a second group of fibers in the plurality of electromagnetically steerable fibers in a second direction (operation 916). In some illustrative examples, the first group of fibers and the second group of fibers differ from each other based on at least one of fiber length, fiber type, or fiber coating (operation 918). In some illustrative examples, applying the electromagnetic field orients only a portion of the plurality of electromagnetically steerable fibers (operation 920).

[0090] In some illustrative examples, curing of a binder of the fiber mixture is performed when a first group of fibers in the plurality of electromagnetically steerable fibers are in a first orientation and a second group of fibers in the plurality of electromagnetically steerable fibers are in a second orientation (operation 922). In some illustrative examples, one of the first orientation or the second orientation is based on flow of the fiber mixture when filling the void. In some illustrative examples, each of the first orientation and the second orientation is based on alignment of a respective electromagnetic source.

[0091] As used herein, when used with a list of items, the phrase "at least one of" means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of the items Item A, Item B, or Item C" may include, but is not limited to, Item A, Item A and Item B, or Item B. This instance may also include Item A, Item B, Item C, or Item B and Item C. Of course, any combination of these items may exist. In other instances, "at least one" may be, for example, but not limited to, two of Item A; one of Item B; 10 of Item C; 4 of Item B and 7 of Item C; or other suitable combinations. The item may be a specific object, thing, or category. In other words, at least one means that any combination of items and multiple items may be used from the list, but not all items in the list are required.

[0092] As used herein, "a plurality" when used to refer to items means one or more items.

[0093] The flowcharts and block diagrams in the different depicted examples show the architecture, functions and operations of some possible implementations of the apparatus and methods in the illustrative examples. In this regard, each box in the flowchart or block diagram may represent at least one of a module, a segment, a function or a part of an operation or a step.

[0094] In some optional implementations of the illustrative examples, one or more functions shown in the blocks may appear in the order shown in the figure. For example, in some cases, two blocks shown in succession may be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order, depending on the functions involved. Moreover, in addition to the blocks shown in the flow chart or block diagram, other blocks may be added. Some blocks may be optional. For example, operations 808 to 832 may be optional. For example, operations 908 to 922 may be optional.

[0095] Illustrative examples of the present disclosure can be found in Fig.10 Aircraft manufacturing and service method 1000 is shown and Fig.11 The description will be made in the context of the aircraft 1100 shown. Fig.10According to an illustrative example, an aircraft manufacturing and service method 1000 is depicted in block diagram form. During pre-production, aircraft manufacturing and service method 1000 may include Fig.11 Specification and design 1002 of aircraft 1100 and material procurement 1004.

[0096] During production, component and subassembly manufacturing 1006 and system integration 1008 of the aircraft 1100 occurs. Thereafter, the aircraft 1100 may be certified and delivered 1010 for entry into service 1012. While in customer service 1012, the aircraft 1100 is scheduled for routine maintenance and service 1014, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

[0097] Each of the processes of aircraft manufacturing and service method 1000 can be performed or executed by a system integrator, a third party, and / or an operator. In these examples, the operator can be a customer. For the purposes of this specification, a system integrator can include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; an operator can be an airline, a leasing company, a military entity, a service organization, etc.

[0098] Reference now Fig.11 , depicts, in block diagram form, a diagram of an aircraft in which an illustrative example may be implemented. In this example, aircraft 1100 is illustrated by Fig.10 Aircraft manufacturing and service method 1000 is produced and may include airframe 1102 and interior 1106 having multiple systems 1104. Examples of systems 1104 include one or more of propulsion system 1108, electrical system 1110, hydraulic system 1112, and environmental system 1114. Any number of other systems may be included.

[0099] Apparatus and methods embodied herein may be used during at least one of the stages of aircraft manufacturing and service method 1000. Fig.10 One or more illustrative examples may be manufactured or used during at least one of component and subassembly manufacturing 1006, system integration 1008, use 1012, or maintenance and service 1014 of the system. Fig.10 The gaps may be filled during at least one of component and subassembly manufacturing 1006 or maintenance and service 1014 .

[0100] The illustrative examples provide composite repairs with improved mechanical properties. The illustrative examples provide composite repairs with directionally oriented fibers within the resin.

[0101] Electromagnetically steerable fibers can be oriented in a desired direction by exposure to an electromagnetic field, at least one of before, during, or after introduction into a composite structure, and before or during curing. The electromagnetically steerable fibers can be oriented before introduction to help reduce the viscosity of the suspension. The electromagnetically steerable fibers can be oriented during introduction into a composite structure to move around three-dimensional obstacles in a void. The electromagnetically steerable fibers can be oriented during introduction into a composite structure to break blockages to flow in a void. The electromagnetically steerable fibers can be oriented before or during resin curing to provide mechanical properties in composite repair.

[0102] The electromagnetically steerable fibers in the illustrative examples are of various sizes and various materials. In some illustrative examples, the fibers are coated to aid adhesion and / or electromagnetic sensitivity.

[0103] The size and number of electromagnetically steerable fibers are selected in such a way that the suspension can still be applied by injection or other desired methods. The number of electromagnetically steerable fibers is sufficient to provide a mechanical benefit. The number of electromagnetically steerable fibers is low enough to provide a suspension with a low enough viscosity to allow the suspension to be introduced into a composite material by injection or other methods.

[0104] A quantity of electromagnetically steerable fibers (e.g., carbon or carbon nanotubes) is mixed with a binder to form a fiber-containing binder. The fiber-containing binder is applied (such as by injection) to a composite repair site. An electromagnetic field is applied to the fiber-containing binder before, during, or after application, and before or during curing to orient the fibers in at least one predetermined direction. The fiber-containing binder is cured to fix the electromagnetically steerable fibers in a plurality of desired directions.

[0105] Adding oriented fibers to a composite repair increases the mechanical properties of the repair. In some illustrative examples, the oriented fibers improve the mechanical properties of the repair in the direction of the oriented fibers. Adding oriented fibers to improve mechanical properties reduces knockdown of the composite repair. In some illustrative examples, at least a portion of the fibers are oriented along the Z-direction of the composite structure. In some illustrative examples, the Z-directed fibers in the composite repair can provide improved durability and fatigue resistance.

[0106] The illustrative examples provide methods and composite material repairs with reduced "knockdown" as applied. The illustrative examples provide methods and composite material repairs that restore at least some of the mechanical properties of the void. The illustrative examples provide composite material repairs with structural properties.

[0107] In addition, this disclosure includes examples according to the following clauses:

[0108] Item 1. A method for performing a composite repair, comprising: forcing a fiber mixture through a composite structure and into a void in the composite structure, the fiber mixture comprising a binder and a plurality of electromagnetically manipulable fibers; applying an electromagnetic field to the fiber mixture within the voids of the composite structure; and curing the binder of the fiber mixture to form the composite repair having structural properties.

[0109] Item 2. The method according to Item 1 further comprises: forming a plurality of injection holes in the composite structure to reach the voids in the composite structure, wherein forcing the fiber mixture to enter the voids comprises forcing the fiber mixture to pass through at least one hole in the plurality of injection holes and enter the voids.

[0110] Clause 3. The method of clause 1 or 2, wherein applying the electromagnetic field to the fiber mixture within the void comprises alternating application of the electromagnetic field while forcing the fiber mixture into the void.

[0111] Clause 4. The method of any of Clauses 1-3, wherein applying the electromagnetic field to the fiber mixture within the void comprises applying pressure to fibers retained in the void while forcing the fiber mixture into the void.

[0112] Clause 5. The method of any of Clauses 1-4, wherein applying the electromagnetic field to the fiber mixture within the void comprises increasing filling of the void with the fiber mixture.

[0113] Clause 6. A method according to any one of clauses 1-5, wherein applying the electromagnetic field to the fiber mixture includes alternately activating the electromagnetic field while forcing the fiber mixture into the gap, and the method further includes: when forcing the fiber mixture into the gap and when the electromagnetic field is not effective, alternately applying a second electromagnetic field within the gap, the second electromagnetic field having a direction different from that of the electromagnetic field.

[0114] Clause 7. The method of any of Clauses 1-6, wherein forcing the fiber mixture into the void comprises vacuum infusing the fiber mixture into the void.

[0115] Clause 8. The method of any of Clauses 1-7, wherein forcing the fiber mixture into the void comprises injecting the fiber mixture into the void.

[0116] Clause 9. The method of any of Clauses 1-8, wherein applying the electromagnetic field to the fiber mixture within the void comprises aligning at least a portion of the plurality of electromagnetically steerable fibers in the void along a Z-direction.

[0117] Item 10. A method according to any one of items 1-9, wherein applying the electromagnetic field to the fiber mixture within the gap includes orienting a first group of fibers among the plurality of electromagnetically manipulable fibers along a first direction, and the method further includes: orienting a second group of fibers among the plurality of electromagnetically manipulable fibers along a second direction.

[0118] Clause 11. A method according to any one of clauses 1-10, wherein curing of the binder of the fiber mixture is performed when a first group of fibers among the plurality of electromagnetically steerable fibers are along a first direction and a second group of fibers among the plurality of electromagnetically steerable fibers are along a second direction.

[0119] Clause 12. The method of Clause 11, wherein the first group of fibers and the second group of fibers differ from each other based on at least one of fiber length, fiber type, or fiber coating.

[0120] Item 13. A method for performing a composite repair, comprising: forcing a fiber mixture through at least one injection hole in a composite structure and into a void in the composite structure, the fiber mixture comprising a binder and a plurality of electromagnetically manipulable fibers; after introducing the fiber mixture into the void, applying an electromagnetic field to the fiber mixture within the void; and curing the binder of the fiber mixture to form the composite repair having structural properties.

[0121] Clause 14. The method of Clause 13, wherein applying the electromagnetic field comprises applying the electromagnetic field during curing.

[0122] Item 15. A method according to Item 13 or 14, wherein applying an electromagnetic field includes orienting a first group of fibers among the plurality of electromagnetically manipulable fibers along a first direction, and the method further includes: applying a second electromagnetic field to the fiber mixture to orient a second group of fibers among the plurality of electromagnetically manipulable fibers along a second direction.

[0123] Clause 16. The method of Clause 15, wherein the first group of fibers and the second group of fibers differ from each other based on at least one of fiber length, fiber type, or fiber coating.

[0124] Clause 17. The method of any of Clauses 13-16, wherein applying the electromagnetic field orients only a portion of the plurality of electromagnetically steerable fibers.

[0125] Clause 18. A method according to any one of clauses 13-17, wherein curing of the binder of the fiber mixture is performed when a first group of fibers among the plurality of electromagnetically steerable fibers are along a first direction and a second group of fibers among the plurality of electromagnetically steerable fibers are along a second direction.

[0126] Clause 19. A method according to any one of clauses 13-18, wherein forcing the fiber mixture to pass through the at least one injection hole comprises injecting the fiber mixture into the void using an injector, the method further comprising: electromagnetically manipulating the electromagnetically manipulatable fibers in the injector before injecting the fiber mixture into the void.

[0127] Article 20. A composite structure having a composite repair having structural properties, the composite structure comprising: a plurality of cured composite plies having voids creating separations within the plurality of cured composite plies; a plurality of injection holes connecting the voids to exteriors of the plurality of cured composite plies; and a cured resin having a plurality of electromagnetically steerable fibers within the separations, forming the composite repair, and configured to transmit forces to the composite plies in contact with the composite repair.

[0128] Clause 21. The composite structure of Clause 20, wherein the plurality of electromagnetically steerable fibers includes a first set of fibers oriented in a Z-direction relative to the plurality of cured composite plies.

[0129] Clause 22. The composite structure of Clause 20 or 21, wherein the plurality of electromagnetically steerable fibers comprises a first set of fibers oriented in a first direction and a second set of fibers oriented in a second direction.

[0130] Clause 23. The composite structure of Clause 22, wherein the first group of fibers and the second group of fibers differ from each other based on at least one of fiber length, fiber type, or fiber coating.

[0131] The description of different illustrative examples is presented for the purpose of illustration and description and is not meant to be exhaustive or limited to examples of the disclosed form. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different illustrative examples may provide different features compared to other illustrative examples. The selected one or more examples are selected and described to best explain the principles of the examples, practical applications, and enable those of ordinary skill in the art to understand the various examples of the present disclosure, as well as various modifications suitable for the intended specific use.

Claims

1. A method (800) of performing composite material repair (204, 502), comprising: forcing (245, 802) a fiber mixture (258) comprising a binder (260) and a plurality of electromagnetically steerable fibers (264, 220, 604) through a composite structure (202, 300, 700) and into voids (210, 304, 704) of the composite structure (202, 300, 700); applying (804) an electromagnetic field (280) to the fiber mixture (258) within the voids (210, 304, 704) of the composite structure (202, 300, 700); and The binder (260) of the fiber mixture (258) is cured (286, 806) to form the composite repair (204, 502) having structural properties (206).

2. The method (800) of claim 1, further comprising: A plurality of injection holes (214, 402) are formed (250, 808) in the composite structure (202, 300, 700) to reach the void (210, 304, 704) in the composite structure (202, 300, 700), wherein forcing (245) the fiber mixture (258) into the void (210, 304, 704) includes forcing (245) the fiber mixture (258) through at least one hole of the plurality of injection holes (214, 402) and into the void (210, 304, 704).

3. The method (800) of claim 1, wherein (814) applying the electromagnetic field (280) to the fiber mixture (258) within the void (210, 304, 704) comprises alternatingly applying the electromagnetic field (280) while forcing the fiber mixture (258) into the void (210, 304, 704).

4. The method (800) of claim 1, wherein (816) applying the electromagnetic field (280) to the fiber mixture (258) within the void (210, 304, 704) includes applying pressure to fibers retained in the void (210, 304, 704) while forcing the fiber mixture (258) into the void (210, 304, 704).

5. The method (800) of claim 1, wherein (818) applying the electromagnetic field (280) to the fiber mixture (258) within the void (210, 304, 704) includes increasing filling of the void (210, 304, 704) with the fiber mixture (258).

6. The method (800) of claim 1, wherein (820) applying the electromagnetic field (280) to the fiber mixture (258) comprises alternately activating the electromagnetic field (280) while forcing the fiber mixture (258) into the void (210, 304, 704), the method further comprising: (822) While forcing the fiber mixture (258) into the gap (210, 304, 704) and when the electromagnetic field (280) is inactive, a second electromagnetic field (284) is alternately applied within the gap (210, 304, 704), the second electromagnetic field (284) having a different direction than the electromagnetic field (280).

7. The method (800) of claim 1, wherein (810) forcing (245) the fiber mixture (258) into the void (210, 304, 704) comprises vacuum infusing the fiber mixture (258) into the void (210, 304, 704).

8. The method (800) of claim 1, wherein (812) forcing (245) the fiber mixture (258) into the void (210, 304, 704) comprises injecting the fiber mixture (258) into the void (210, 304, 704).

9. The method (800) of claim 1, wherein (824) applying the electromagnetic field (280) to the fiber mixture (258) within the void (210, 304, 704) comprises aligning at least a portion of the plurality of electromagnetically steerable fibers (264, 220, 604) in the void (210, 304, 704) along a Z-direction.

10. The method (800) of claim 1, wherein (826) applying the electromagnetic field (280) to the fiber mixture (258) within the void (210, 304, 704) comprises orienting a first group of fibers (222, 606) of the plurality of electromagnetically steerable fibers (264, 220, 604) in a first direction (224), the method further comprising: A second group of fibers (228, 608) of the plurality of electromagnetically steerable fibers (264, 220, 604) are oriented (828) in a second direction.

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