Method for forming a feature in a piece of composite material

1. A method for forming a feature in a piece of engineered composite material, the method comprising the steps of:

laying a first set of layers of a composite material for said piece on a tool surface;

removing a first part of said first set of composite layers;

forming a first mandrel comprising said removed part of said composite layers, said first mandrel configured to conform to said feature in said piece;

inserting said first mandrel in place of said removed first part of said first set of layers;

laying a second set of layers of a composite material for said piece over said first set of composite layers and said first mandrel;

curing said piece; and

removing said first mandrel.

2. A method according to claim 1 in which said forming a first mandrel comprises wrapping said removed first part of said first set of composite layers in release film.

3. A method according to claim 1 in which one or more layers are removed from said removed first part of said first set of composite layers prior to forming said first mandrel.

4. A method according to claim 1 in which said tool surface comprises a first rebate and said first mandrel conforms to said first rebate and comprises a lower part formed from said removed first part of said first set of composite layers and an upper fixed part conforming to said feature to be formed in said piece, said removed first part of said first set of composite layers being the part of said first set of composite layers laid over said first rebate.

5. A method for forming a feature in a piece of engineered composite material, the method comprising the steps of:

laying a first set of layers of a composite material for said piece on a tool surface;

removing a first part of said first set of composite layers;

forming a first mandrel comprising said removed part of said composite layers, said first mandrel configured to conform to said feature in said piece;

inserting said first mandrel in place of said removed first part of said first set of layers;

curing said piece; and

removing said first mandrel in which said tool surface comprises a first rebate and said first mandrel conforms to said first rebate and comprises a lower part formed from said removed first part of said first set of composite layers and an upper fixed part conforming to said feature to be formed in said piece, said removed first part of said first set of composite layers being the part of said first set of composite layers laid over said first rebate, in which said first rebate forms a trough, and said first set of composite layers is laid across said trough so as to enable said first mandrel to form an aperture in said piece.

6. A method according to claim 4 in which said first rebate is arranged to form a first trough within a second rebate in the form of a second trough, said method comprising the further steps of

prior to laying said second set of composite layers, removing the second part of said first set of composite layers laid over said second rebate and inserting a second mandrel in said second trough, said second mandrel comprising a lower part formed from said removed second part of said first set of composite layers and an upper fixed part conforming to said second trough; and

after laying said second set of composite layers and prior to curing said piece, removing a part of said second set of composite layers and adding said removed part of said second set of layers to said lower part of said first mandrel.

7. A method according to claim 6 in which said second rebate is formed in two parts running either side of said first rebate.

8. A method according to claim 6 in which said second rebate runs continuously around said first rebate.

9. A method according to claim 1 wherein said composite material comprises a thermoplastic resin and said curing step comprises the setting of said thermoplastic resin.

10. A method for forming a piece of composite material to include a formed feature, the method comprising the steps of:

a) laying a first set of composite layers for said piece on a tool surface;

b) removing a part of said first set of composite layers;

c) forming a mandrel from said removed part of said first set of layers wrapped in a release film, said mandrel conforming to a feature to be formed in said piece;

d) inserting said mandrel in place of said removed part of said first set of composite layers;

e) laying a second set of composite layers for said piece over said first set of composite layers and said mandrel; and

f) curing and finishing said piece.

11. A method according to claim 10 wherein said composite material comprises a thermoplastic resin and said curing step comprises the setting of said thermoplastic resin.

12. A method for forming a feature in a piece of composite material, the method comprising the steps of:

a) laying a first set of composite layers for said piece on a tool surface;

b) removing a first part of said first set of composite layers;

c) inserting a first mandrel in place of said removed first part of said first set of composite layers, said first mandrel being arranged to conform to a feature to be formed in said piece and to have substantially the same rate of compaction during curing as said removed first part of said set of composite layers;

d) laying a second set of composite layers for said piece over said first set of composite layers and said first mandrel; and

e) curing said piece, wherein said first mandrel is formed from said removed first part of said first set of composite layers and said removed first part of said first set of composite layers is wrapped in release film.