Abstract:
Method and apparatus for the manufacture of fiber reinforced structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling and during the curing of the fiber elements.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a divisional of application Ser. No. 09/070,445, filed Apr. 30, 1998, now U.S. Pat. No. 6,050,315. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a method and apparatus for the manufacture of fiber reinforced structures. More specifically, the present invention relates to a method and apparatus for the fabrication of composite structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. 
     2. State of the Art 
     It is desirable to have inexpensive, strong, lightweight, easily manufactured, dimensionally accurate components in a variety of sizes and geometries for use in aircraft and aerospace applications. Composite reinforced, or “grid-stiffened”, shell structures, such as shrouds, casings, fuel tanks, airfoils, or wing skins, and fuselage panels, provide recognized advantages in aerospace applications over conventional metal assemblies, typically of aluminum or titanium, in terms of relatively lower weight and higher strength for the composite structures. However, meeting such criteria for components is difficult. The acceptance of all-composite structures has been hampered by the lack of demonstrated, repeatable, and inexpensive fabrication methodology and apparatus for effecting such in an automated manner. Composite structures have been found in high-performance military aerospace applications, where composite structures are formed in an non-automated manner at great expense. In non-aerospace applications, composite structures are more limited to applications where they can be formed as simple structures on existing machines. However, it is desirable to form complex reinforced composite structures for a wide variety of applications which are price competitive with metal structures and have lower weight and equal or better strength than such metal structures. 
     For example, commercial aircraft are typically powered using turbofan type engines. A turbofan type engine includes a ducted fan, a large diameter, axial-flow multi-stage compressor, as the primary source of thrust by the engine while the gas generator portion of the engine provides a smaller amount of the engine&#39;s thrust. Each stage of the ducted fan includes a number of fan blades attached to a rotating fan disc or hub to compress air, the compressed air flowing from the fan and expanding through a nozzle to provide thrust to move the aircraft. Depending upon the size of the engine, the diameter of each stage of the ducted fan may be approximately one meter to several meters or more in diameter and rotate at several thousand revolutions per minute. Each fan blade attached to a fan disc or hub is a highly stressed structure due to the forces acting on the blade from compressing the air flowing therearound and from the centrifugal forces acting on the blade during rotation of the engine. 
     Since weight is of concern in aircraft engines, it is desirable to provide the lightest engine possible to meet the operational criteria for the aircraft while providing the required aircraft operational safety. One of the desired operational safety characteristics for a turbofan aircraft engine is that if a fan blade catastrophically fails during engine operation, the blade or pieces of the blade be contained or caught within the fan housing structure to prevent damage to the aircraft, its cargo, and the surrounding engine and aircraft environment. Typically, aircraft manufacturers have required that the fan housing be such a structure for the engine, thereby making the fan housing one of the heaviest engine components. 
     The design of an inexpensive, strong, lightweight, easily manufactured, dimensionally accurate fan housing in a variety of sizes and geometries for use in aircraft is a formidable task. For instance, the fan housing must be strong enough to contain the energy of a fan blade when the failure occurs at maximum engine speed, must be dimensionally accurate over a range of engine operating conditions, must be easily manufactured at a reasonable cost, must be lightweight, etc. Typically, fan housings have been metal structures using a variety of reinforcing grids, typically formed of metal. However, such fan housings are expensive, are difficult to manufacture, require extensive tooling to manufacture to close tolerances, and are heavy. 
     In other instances, some fan housings have been composite type structures including metal components and non-metallic or organic type reinforcing components in an attempt to provide a high-strength, lightweight structure capable of containing a broken fan blade. However, such composite type structures are difficult to construct because the reinforcing structure of non-metallic materials for the fan housing has been difficult and expensive to construct. Typically, such a non-metallic reinforcing structure has employed an isogrid type structure which is difficult to reliably fabricate in quantities. The isogrid type structure is efficient in providing reinforcement for the fan housing and the ability to catch a broken fan blade while maintaining its strength and integrity even with a portion missing or broken. A composite isogrid structure may require internal or external reinforcing elements or stiffeners, ribs, adjacent a continuous shell structure, to provide enhanced stiffness to the shell structure in terms of torsional and bending resistance. The larger the shell structure, the greater the reinforcing requirement. The reinforcing elements may be discrete and remote from each other or, preferably, are in a grid structure. One favored grid structure is an isogrid of reinforcing elements at angles of approximately 60° with respect to an adjacent element. 
     Typically, such composite isogrid structures have been fabricated by hand by applying resin (epoxy) impregnated fiber element “tows” in a grid-like pattern using soft, imprecise tooling of wood, resilient materials, etc. which affects the isogrid structure&#39;s repeatability in manufacture, dimensional tolerance variation, structural integrity, cost, etc. A number of tows are typically laid-up on a mandrel or other tooling in vertically superimposed, or stacked, relationship to define each rib of the grid. The tows are then cured simultaneously under heat and pressure with a contiguous composite shell. However, such a process is not repeatable and the product not reproducible. Alternately, stiffeners may be fabricated by automated application, or “winding”, of the fiber elements in the form of continuous filaments onto a cylindrical mandrel. However, filament winding has exhibited perceptible deficiencies in terms of inaccuracy of fiber placement. as well as compaction problems of the placed fiber. Also, the filament winding generates an excess of fiber scrap since it requires a continuous turnaround path when each end of a mandrel is reached; the filament turns around at the ends of the mandrel do not form part of the final structure, and, so, are cut off and discarded. Filament winding techniques provide no capability to “steer” the fiber filament to accommodated desired variations from a preprogrammed path to place fiber on complex geometry mandrels, including those exhibiting concave exterior portions, or to terminate fiber element placement at a target point on tooling and restart the application of a new fiber element at a new target point. Filament winding has particularly severe limitations where stiffening members cross or intersect, due to the inability to eliminate or reduce fiber element build-up at the nodes where fiber elements are oriented in two or more directions cross. Furthermore, filament winding techniques lack the capability to place fiber at a zero degree angle, i.e., parallel, to the longitudinal axis of rotation of the mandrel. Therefore, a need exists for a method and apparatus for the fabrication of composite structures, such as an isogrid structure, to maintain the integrity, reliability, repeatability of manufacture, dimensional control, and cost of the structure. A need exists for an apparatus capable of placing discrete fiber elements in desired lengths and at desired angles along specified paths onto tooling so as to form stiffening structures onto which a blanket of composite fibers may be laid up to form the desired structure and the fibers cured to yield the desired structure. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a method and apparatus for the manufacture of fiber reinforced structures. More specifically, the present invention relates to a method and apparatus for the fabrication of composite structures wherein tooling and a delivery head are employed for the placement of discrete, elongated fiber elements in a mutually superimposed relationship to define reinforcement or stiffening members on fiber elements for the interiors or exteriors of composite shells and the consolidation of the fibers to form the cured composite structure. The present invention includes the fiber placement apparatus and the composite structure tooling as well as their use for the manufacture of reinforced structures. The apparatus includes a delivery head and hard tooling for the fiber elements to be applied thereto. A consolidation medium is provided for the positioning and control of the fiber elements on the hard tooling as well as during the curing of the fiber elements. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
     For a more complete understanding of the present invention and the advantages thereof, reference should be made to the following detailed description taken in connection with the accompanying drawings in which: 
     FIG. 1 is an enlarged, right-hand isometric view of a preferred embodiment of the apparatus of the present invention; 
     FIG. 2 is a left-hand isometric view of the apparatus shown in drawing FIG. 1; 
     FIG. 3 is a frontal elevational view of the apparatus shown in drawing FIG. 1; 
     FIG. 4 is a top elevational view of the apparatus shown in drawing FIG. 1; 
     FIG. 5 is a side sectional elevation of the apparatus shown in drawing FIG. 1; 
     FIG. 6 is a partial cross-sectional view of intersecting groups of stacked tows at a grid node where two stiffening ribs cross; 
     FIG. 7 is a top elevation of abutting tows applied at intersecting angles according to the present invention; 
     FIG. 8 is a view of a portion of the tooling used in a first embodiment of the present invention; 
     FIG. 9 is bottom view of a tooling block used in the present invention; 
     FIG. 10 is a side view of the tooling block illustrated in drawing FIG. 9 used in the present invention; 
     FIG. 11 is a bottom view of another tooling block used in the present invention; 
     FIG. 12 is a side view of the tooling block illustrated in drawing FIG. 11 used in the present invention; 
     FIG. 13 is a view of a portion of the tooling used in a first embodiment of the present invention to mate with the portion of the tooling illustrated in drawing FIG. 1 of the present invention; 
     FIG. 14 is a view of a portion of the tooling of the first embodiment of the present invention in a circular drum type configuration; 
     FIG. 15 is a view of a portion of the tooling of the first embodiment of the present invention in a circular drum type configuration with a cover thereon; 
     FIG. 16 is a top view of a portion of the tooling used in the present invention with material located thereon; 
     FIG. 17 is a cross-sectional view of a portion of the tooling of the first embodiment of the present invention and a portion of a grid structure formed thereon; 
     FIG. 18 is a cross-sectional view of a portion of the tooling of a second embodiment of the present invention and a portion of a grid structure formed thereon; 
     FIG. 19 is a top view of a portion of the tooling of the present invention and a portion of a grid structure formed thereon; 
     FIG. 20 is a cross-sectional view of a portion of the tooling for a third embodiment of the present invention; 
     FIG. 21 is a cross-sectional view of a portion of the tooling for a fourth embodiment of the present invention; 
     FIG. 22 is a cross-sectional view of a portion of the tooling for a fifth embodiment of the present invention; 
     FIG. 23 is a cross-sectional view of a portion of the tooling for a sixth embodiment of the present invention; 
     FIG. 24 is a cross-sectional view of a portion of the tooling for a seventh embodiment of the present invention; 
     FIG. 25 is a cross-sectional view of a portion of the tooling for an eighth embodiment of the present invention; 
     FIG. 26 is a cross-sectional view of a portion of the tooling for a ninth embodiment of the present invention; 
     FIG. 27 is a top view of a portion of the tooling used for the eighth and ninth embodiments of the present invention; and 
     FIG. 28 is a cross-sectional view of a portion of the tooling for a ninth embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to drawing FIGS. 1 through 6, the structure and operation of a preferred embodiment  1000  of the composite fiber element placement apparatus of the present invention will be described. 
     Fiber placement apparatus  1000  is mounted to offset mounting adapter  1012 , which is affixed to a mounting frame  202  (shown in broken lines in FIG. 1) of a carriage  200  or other mounting structure proximate a mandrel or other tooling to which fiber element tows are to be applied by apparatus  1000 . An upright base mount  1014  secures apparatus  1000  to mounting adapter  1012  via a plurality of cap screws  1016 , which extend through washers  1018 , and the heads of which are contained within counterbores  1020  in the forward surface of base mount  1014 . Of course, other means might be employed to secure apparatus  1000  to mounting adapter  1012  or directly to a mounting frame  202  or other mounting structure. 
     A frame subassembly  1026  is horizontally slidably mounted to base mount  1014  so as to be capable of controlled travel toward and away from the mandrel or other tooling  10  to which fiber tows are to be applied. Such controlled travel is effected in part by supporting the weight of apparatus  1000 , but for base mount  1014  and mounting adapter  1012 , on parallel linear slides  1028  (see FIG. 3) which extend transversely to base mount  1014 . In addition, an actuator, preferably in the form of a double-acting pneumatic cylinder  1030 , is secured at the rear end of apparatus  1000  to base mount  1014 , and the shaft  1032  of pneumatic cylinder  1030  is secured to frame subassembly  1026  at  1034  (FIG.  5 ). Cylinder  1030  thus effects fore-and-aft movement of the apparatus components mounted to frame subassembly  1026  responsive to pneumatic pressure opposingly applied through air lines  1036  and under control of a programmed machine controller  1150 . By way of example only, a preferred fore-and-aft travel distance for frame subassembly  1026  is approximately 2.5 inches. A measuring gage encoder  1038 , such as the Model P40 Measuring Gauge, available from Gurley Precision Instruments of Troy, N.Y., is secured to frame subassembly  1026  and located to detect the precise position of frame subassembly  1026  responsive to travel of spring-loaded encoder probe  1040 , which remains in contact with base mount  1014 . 
     A spool  1042  having composite fiber element  1044  wound therearound is carried by frame subassembly  1026 , preferably mounted in a cantilevered fashion on a spindle extending horizontally from upstanding strut  1046  secured to base  1048  of creel  1050 . Creel  1050  also includes removable hood  1052 , which extends over spool  1042  and which is releasably secured to each side of creel base  1048  by clamp assemblies  1054 . The spool holder zone  1056  within the creel  1050  is temperature controlled by a flow of conditioned air thereinto through cold air inlet port  1058  (see FIG. 2) fed by vortex cooler  1059  in order to preclude the impregnated fiber from becoming too tacky or too inflexible on the spool. The air flow exits the spool holder zone  1056  through gaps between the hood  1052  and portions of frame subassembly  1026 . 
     Fiber element  1044 , which may comprise a single tow of (for example) one-eighth (0.125) inch or one-quarter (0.25) inch width and comprised of a plurality of mutually parallel, epoxy resin-impregnated carbon fibers, which are fed downwardly from the rear of spool  1042  onto and about rear guide, or redirect, roller  1060  mounted to frame subassembly  1026  to change the direction of fiber element  1044  approximately 90° and toward the tooling. Tray redirect roller  1062 , also mounted to frame subassembly  1026 , in turn directs fiber element  1044  to guide tray  1070 . Rear redirect roller  1060  is laterally sized to accommodate any tow width usable with apparatus  1000 , but tray redirect roller  1062  is preferably sized to accommodate a specific tow, or multiple-tow band, width, extending flanges  1064  of roller  1062  laterally constraining fiber element  1044 . Rollers  1060  and  1062  are preferably provided with a suitable covering of, for example, polytetrafluoroethylene (sold as Teflon® polymer) to substantially preclude adhesion of the resin-impregnated fiber element  1044  thereto. 
     Guide tray  1070 , also mounted to frame subassembly  1026 , maintains precise positional control of fiber element  1044  as it progresses through the cut/add module  1072  and to the guide or delivery chute  1100 . Servo motor  1080  powers drive roller  1082  through timing pulley  1084  and timing belt  1086 , and clamp roller  1088  is pivotally mounted at  1090  and selectively powered pneumatically by actuator  1092  to press fiber element  1044  against drive roller  1082 . Drive roller  1082  and clamp roller  1088  are provided with a suitable covering such as urethane to provide traction and surface compliance to advance fiber element  1044  as clamp roller  1088  is actuated against drive roller  1082 . Servo motor  1080  is operated in a closed loop position mode to ensure that fiber element  1044  reaches the tooling at the target location. Guide or delivery chute  1100 , which receives fiber element  1044  from guide tray  1070  and is secured thereto, is laterally sized to precisely laterally constrain fiber element  1044  as it travels to guide scoop  1102  adjacent compaction or delivery roller  1104 , which is also precisely laterally sized to the specific tow or band width of the fiber element  1044 . Double-acting pneumatic knife actuator  1106  is positioned transversely to the path of fiber element  1044  through guide chute  1100  so that knife blade  1108  may be positively advanced through severance gap  1110  in guide chute  1100  to contact fiber element  1044  and sever it into a tow or band of discrete length adjacent anvil  1112 . Knife actuator  1106  is selectively powered through compressed air lines  1114 . It should be understood that clamp roller actuator  1092  and knife actuator  1106 , or either of them, may be driven electrically rather than pneumatically, and that a single-acting knife actuator using a spring return may also be suitably employed in lieu of a double-acting actuator. 
     Optionally, a second vortex cooler  1059  may be employed to generate cooling air delivered by tubing or other conduit  1061  to the cut/add module  1072  in the vicinity of the path of fiber element  1044  therethrough to keep rollers  1082  and  1088 , knife blade  1108 , anvil  1112  and guide tray  1070  cool to reduce resin buildup from the passage of fiber element  1044 . 
     Compaction roller  1104  is an unpowered, or free-wheeling, roller which rotates responsive to fiber element  1044  being paid out onto the tooling at a target location. Guide scoop  1102 , extending from the end of guide chute  1100  follows the curvature of the outer periphery of compaction roller  1104  and is spaced therefrom a substantially continuous radial distance slightly larger than a thickness of fiber element  1044 . The outer periphery of compaction roller  1104  is preferably covered with an elastomeric material, such as rubber, conformable to the surface contour of the mandrel or other tooling  10  or to previously-applied tows to ensure consistent and uniform application, compaction and adherence of the tows. As may be seen in drawing FIGS. 1 and 3, roller  1104  is preferably biased toward a central position on its shaft  1120 , which is mounted at each end to nose piece  1121 , by coil springs  1122  acting on both sides of the hub of roller  1104 . The precise lateral position of roller  1104  during operation is detected by encoder  1124 , probe  1126  of which lies adjacent one side of roller  1104 . Encoder  1124  may also comprise the previously-mentioned Model P40 Measuring Gauge from Gurley Precision Instruments. As a result of this positional monitoring in combination with the spring-biased, free-floating lateral action of the compaction roller  1104 , the lateral position of roller  1104  on shaft  1120  is reported back to the machine controller  1150  so that the motion of the apparatus  1000  may be fine-tuned for optimum tracking of the mandrel for fiber delivery and compaction in a “self-teach” mode. In addition, the floating action of the compaction roller  1104  serves to protect the tooling from damage which might occur if the lateral motion of the roller  1104  was constrained. 
     It should be noted again at this juncture, and specifically with reference to drawing FIG. 5, that the path of fiber element  1044  from spool  1042  to compaction roller  1104  is relatively simple and unconvoluted in comparison to conventional apparatus for fiber element application. For example, the path of fiber element  1044  is redirected far less than 180°, and actually only in the range of about 100° to about 130° (depending on how full spool  1042  is), from its initial downward path from spool  1042  until it reaches the periphery of compaction roller  1104 , so that undue bending and twisting of fiber element  1044  is eliminated, preserving the integrity of the fiber element. In addition, it should also be noted that the path of fiber element  1044  between tray redirect roller  1062  and the periphery of compaction roller  1104  is substantially linear to better ensure that the maximum surface area of fiber element  1044  is presented to tooling  10  (or to a previously-applied tow) and pressed firmly thereagainst with the individual fibers of the element aligned in parallel and with an even distribution of resin. 
     Compaction roller  1104  applies fiber element  1044  to the tooling using compaction force against tooling  10 , preferably under elevated temperature conditions. Compaction force is provided by double-acting pneumatic cylinder  1030 , previously described. Heat is provided to the compaction zone on the tooling  10  to render the epoxy resin of fiber element  1044  tacky to enhance adherence thereto or to previously-laid tows by a hot air torch  1130  (FIG.  1 ), the fan-shaped nozzle  1132  of which lies immediately below compaction roller  1104  and guide scoop  1102 . 
     In operation of apparatus  1000  of the invention, fiber element  1044  is fed to compaction roller  1104  under control of programmed machine controller  1150 . The target start point on the tooling  10  for commencement of application of a discrete segment, or tow, of fiber element  1044  has been selected, and fiber element  1044  has been advanced to compaction roller  1104  by the cooperation of drive roller  1082  and clamp roller  1088 . Apparatus  1000  may either be mounted to a carriage  200  traversable in a direction parallel to the longitudinal axis or direction of elongation of the mandrel or other tooling  10  through mounting adapter  1012  to effect lateral movement parallel thereto to facilitate application of fiber element tows  1162  at positions along the entire length thereof, or the mandrel or other tooling  10  may be mounted for such lateral movement past apparatus  1000 . Preferably, carriage  200  comprises part of a six-axis fiber placement machine of the type disclosed in U.S. Pat. No. 4,867,834, so that tows may be placed at any position and angle on the mandrel or other tooling. The referenced axes include the aforementioned longitudinal carriage movement, as well as radial carriage movement transverse to the longitudinal axis of the mandrel, roll, pitch and yaw movement of the apparatus  1000  with respect to carriage  200 , and rotation of the mandrel or other tooling  10  about its longitudinal axis. As used herein with respect to movement of the apparatus, “roll” identifies rotational motion about a horizontal axis perpendicular to the mandrel axis, “pitch” identifies rotational motion about a horizontal axis parallel to the mandrel axis, and “yaw” identifies rotational motion about a vertical axis. Most preferably, carriage  200  comprises part of a multi-axis fiber placement machine affording seven axes of motion for tow placement, including the aforementioned six as well as an ability to alter the elevation of apparatus  1000 . It should again be noted that the self-contained nature of the apparatus of the present invention, including its own supply of fiber element  1044 , facilitates rotation of apparatus  1000  about an axis perpendicular to the tooling  10  and thus permits running of tows parallel to the tooling axis. 
     In either case, when the compaction roller  1104  is adjacent the target fiber application start point, the apparatus  1000  is driven forward by pneumatic cylinder  1030  against the tooling  10 , which rotates about its axis while fiber element  1044  is applied thereto and compacted thereagainst by roller  1104  while heat is applied by torch nozzle  1132 . Drawing FIG. 5 schematically depicts application of fiber element  1044  in the form of a tow  1162  (shown in broken lines) to tooling  10 . Of course, relative movement of either tooling  10  or apparatus  1000  along the longitudinal axis of the tooling  10  may be simultaneously effected so that a tow  1162  comprising a portion of fiber element  1044  may be applied in any desired angular direction. When the controller  1150  detects that an appropriate length of fiber element  1044  has been paid out from spool  1042 , it actuates knife actuator  1106  at a time that ensures that the “tail” of the tow downstream of knife actuator  1106  is the correct length to complete application of the tow  1162  to the tooling  10  at a target endpoint. The apparatus  1000  and tooling are then moved, and/or rotated in the case of the tooling  10 , to a new tow target start point, fiber element feed is restarted, and the new tow applied and compacted under heat and pressure. By multiple applications of superimposed or stacked tows  1162 , reinforcing ribs or “stiffeners”  1164  may be built up on the tooling or mandrel  10  as shown in drawing FIG.  6 . Further, and also as shown in drawing FIG. 6, tows  1162  may be easily laid in different directions so as to overlap or intersect at nodes  1166  to define a grid pattern of stiffeners  1164  as previously mentioned. The cut and add capability of apparatus  1000  also facilitates fabrication of nodes with abutting, rather than overlapping, tows  1162  running in different directions, or a combination of abutting and overlapping tows  1162 , as dictated by the programming of controller  1150 . It is further contemplated that the knife actuator, which also carries anvil  1112 , may be mounted so as to rotate about an axis A (see FIG. 5) intersecting and perpendicular to the path of fiber element  1044  through guide chute  1100  responsive to rotational drive unit R shown schematically in broken lines under control of controller  1150 . In such a manner, when using a knife blade  1108  and anvil  1112  of greater width than fiber element  1044  to be severed, the cut angle of the fiber element  1044  may be changed as required to match the cut angle of the knife blade  1108  to the crossover angle between tows  1162  being applied in different directions so that a leading end surface  1170  of a first tow  1162  and a trailing end surface  1172  of a second tow  1162  (see FIG. 7) will each lie substantially parallel to a side  1174  of a previously-applied tow  1162  against which that respective end surface abuts (leading and trailing ends  1170  and  1172  shown slightly spaced from sides  1174  for clarity in FIG.  7 ). 
     Referring to drawing FIG. 8, illustrated is a portion of the tooling assembly  10  of the present invention including a portion of the hard tooling  12  and the consolidation medium  14 . The hard tooling  12  may be formed in any desired convenient shape or configuration, such as flat, annular, circular, conical, pyramidal, rectangular, etc, for the manufacture of a reinforced structure, such as an isogrid structure, or any convenient desired composite reinforced structure. In this instance, the portion of the hard tooling  12  includes a metal sheet  16  having a plurality of recessed pockets  18  therein having, in turn, a plurality of apertures  20  therein and a plurality of ribs  22  for the support of the fiber element (not shown) applied thereto extending between the pockets  18 . The recessed pockets  18  and ribs  22  may be any desired shape or configuration for the desired composite structure to be formed. The ribs  22  may be at any desired angle with respect to an adjacent rib  22  and/or may extend parallel to the direction of the rotational axis  25  of a mandrel upon which the tooling  12  may be installed, such as rib  22 ′ of tooling  12 . The intersection of the ribs  22 ,  22 ′ occurs at nodes  23  of the tooling  12 , such nodes  23  being any desired shape formed by the intersection of the ribs  22 ,  22 ′. Each recessed pocket  18  may have any desired number of apertures  20  therein used to receive and retain a portion of the consolidation medium  14  therein. The ribs  22 ,  22 ′ may be of any desired width or shape, depending upon the composite structure to be formed on the hard tooling by the application of fiber element thereto. If desired, the hard tooling  12  may not have recesses  18  formed therein but merely contain a plurality of apertures  20  therein. 
     The consolidation medium  14  includes a plurality of individual consolidation blocks  24 , each block having a shape to fit within a corresponding recessed pocket  18  of the hard tooling  12 , the shape of each consolidation block  24  being the desired shape of the corresponding recessed pocket  18 . Each consolidation block  24  has a thickness or height sufficient to allow the formation of the desired composite structure on the hard tooling  12  when the consolidation block  24  has been assembled thereon in a corresponding recessed pocket  18 . Each consolidation block  24  is formed from any desired structural material capable of holding its shape during the formation of the composite structure during fabrication and curing, such as steel, aluminum, titanium, alloys thereof, silicon elastomeric material, high durometer elastomeric material, high melting temperature plastic material, ceramic material, etc. The consolidation blocks  24  and the hard tooling  12  should be easily machinable or formable for the desired composite structure to be formed therewith as well as it is desirable for them to be light-weight for handling purposes. The consolidation blocks  24  are retained within the recessed pockets  18  of the hard tooling by any suitable means, such as pin connections, threaded connections, resilient spring connections, etc. For precision control of the composite structure to be formed using the hard tooling  12 , each consolidation block  24  should fit within its corresponding recessed pocket  18  with a minimum of clearance, such as, for instance, 0.010 inches clearance. In this manner, the composite structure to be formed using the consolidation blocks  24  and hard tooling  12  may be precisely controlled dimensionally. 
     Referring to drawing FIG. 9, a consolidation block  24  is illustrated from the bottom thereof. The block  24  includes a plurality of pins or nubs  30  thereon which are received within apertures  20  of the sheet  16  of the hard tooling  12  (see FIG.  1 ). As stated, the consolidation block  24  may be of any desired shape to form the composite structure using the consolidation blocks  24  and hard tooling  12  as well as any desired number of pins  30  to be included on a block  24  to precisely retain block  24  within the recessed pocket  18 . 
     Referring to drawing FIG. 10, a consolidation block  24  of consolidation medium  14  is illustrated from a side view with the plurality of pins  30  thereon which are received within apertures  20  of the sheet  16  of hard tooling  12  to locate and retain the block  24  within the recessed pocket  18 . The pins  30  may be of any desired length, size, and suitable material for the precise location and retention of the consolidation block  24  on the hard tooling  12 . Each pin may, if desired, include an annular chamfered surface  32  thereon to aid in the insertion of the block  24  within an aperture  20  of the sheet  16  of hard tooling  12 . 
     Referring to drawing FIG. 11, a consolidation block  24  of consolidation medium  14  is illustrated from the bottom thereof having alternative resilient or spring type connections  34  thereon. As illustrated, the consolidation block  24  includes a plurality of resilient spring type connections  34  thereon which are received within apertures  20  of the sheet  16  of the hard tooling  12  (see FIG.  8 ). As stated, the consolidation block  24  may be of any desired shape to form the composite structure using the consolidation blocks  24  and hard tooling  12  as well as any desired number of resilient spring type connections  34  to be included on a block  24  to precisely retain block  24  within the recessed pocket  18 . The resilient spring type connections  34  may have a pin (not shown) or suitable member inserted through the end portion  36  thereof to retain the resilient spring type connection in the aperture  20  in the sheet  16  of the hard tooling  12 . 
     Referring to drawing FIG. 12, a consolidation block  24  of the consolidation medium  14  is illustrated from a side view with the plurality of resilient spring type connections  34  thereon which are received within apertures  20  of the sheet  16  of hard tooling  12  to locate and retain the block  24  within the recessed pocket  18 . The resilient spring type connections  34  may be of any desired length, size, and suitable material for the precise location and retention of the consolidation block  24  on the hard tooling  12 . Each resilient spring type connection  34  may, if desired, include an end portion  36  thereon to engage a pin (not shown) or other suitable member to retain the resilient spring type connection  34  within an aperture  20  of the sheet  16  of hard tooling  12 . 
     Referring to drawing FIG. 13, a mating piece of tooling  42 , also preferred to be hard tooling, is illustrated which mates with hard tooling  12  and consolidation blocks  24  after the formation of a desired composite structure thereon using tows of fiber elements applied to the tooling  12 , the mating piece of tooling  42  to be used during the curing of the composite structure. The mating piece of tooling  42  includes a hard tooling sheet  46  having a plurality of recessed pockets  48  therein to receive a portion of a corresponding consolidation block  24  of consolidation medium  14  therein and having a plurality of ribs  44 ,  44 ′ formed between the recessed pockets  48  located to correspond to the ribs  22 ,  22 ′ of the sheet  16  of the hard tooling  12  to retain the composite structure therebetween during curing. The ribs  44 ′, like ribs  22 ′ on hard tooling  12 , extend parallel to the rotational axis  25  of the mandrel on which hard tooling  12  may be installed. The mating piece of tooling  42  is formed as a mirror image of the hard tooling  12  and consolidation blocks  24 . The mating piece of tooling  42  may be formed of any desired material for use in the curing process of the composite structure having sufficient strength during the elevated temperatures of the curing process of the composite structure. 
     Referring to drawing FIG. 14, hard tooling  112  in an annular configuration having consolidation blocks  124  thereon is illustrated for forming an annular shaped composite structure thereon. The hard tooling  112  includes a hard sheet  116  of any suitable material having a plurality of consolidation blocks  124  retained thereon with recessed pockets  118  having ribs  122 ,  122 ′ formed therebetween upon which the composite structure is formed. The hard tooling  112  may be of any suitable, convenient shape for the forming of the annular shaped composite structure thereon for use on any suitable apparatus for the support of the hard tooling  112 . The consolidation blocks  124  may be formed as described herein of any desired shape using any suitable, desired connection to the hard tooling  112  to retain the consolidation blocks  124  in the recessed pockets  118  therein. The hard tooling  112  may be formed in segments, any suitable, desired number and shape, which are secured together to form the annular hard tooling  112 , the segments allowing the removal of the tooling  112  from the interior of the cured composite structure. The hard tooling  112  may include flanges  126  thereon for use in the formation and curing of the composite structure formed on the hard tooling  112 , the hard tooling  112  having a rotational axis  25  for the formation of the composite structure therearound. 
     Referring to drawing FIG. 15, the hard tooling  112  is illustrated having a cover  130 , preferably of hard tooling, installed over the area of the tooling  112  containing the recessed pockets  118  and consolidation blocks  124  (see FIG. 14) for use in the curing of the composite structure formed on the hard tooling  112 . The cover  130  may be of any suitable material for use during curing of the composite structure at an elevated temperature, such as aluminum, titanium, steel, etc. The cover  130  and the hard tooling  112  should be lightweight for handling purposes as well as possess sufficient strength for the loading of the composite structure during the curing process. The cover  130  may be secured to the hard tooling  112  by any suitable fastener arrangement, such as the use of clamps and threaded fasteners  132 . 
     Referring to drawing FIG. 16, a portion of the hard tooling  12  or  112 , without a cover  130  thereover, is illustrated at the juncture of four consolidation blocks  24  or, alternately,  124  (not shown). The consolidation blocks  24  may each include, if desired, a profiled edge thereon to retain the fiber material on the hard tooling  12  or  112  during the formation and curing of the composite structure thereon. The profiled edge  26  may be of any suitable shape, both vertically or longitudinally around a portion or the entire periphery of the consolidation block  24 , to retain or contain the fiber material and the coating on the hard tooling  12  or  112 . 
     Referring to drawing FIG. 17, a portion of a composite structure formed on hard tooling  12  or  112  (not shown) with consolidation blocks  24  and cover  130  is illustrated as depicted along lines  9 — 9  of drawing FIG.  16 . As illustrated, the consolidation blocks  24  have the edge  26  thereof having a suitable vertical profile adjacent the composite structure being formed on ribs  22  (or rib  22 ′) of the hard tooling  12 . The edge  26  may be of any suitable shape and may vary from consolidation block  24  to adjacent consolidation block  24 , as illustrated. The purpose of the profiled edge  26  on the consolidation block  24  is to confine and retain the fiber material  200 , comprised of tows of fiber elements  1162  hereinbefore described, which includes fibers  202  and coating material  204  thereon, i.e., a carbon fiber impregnated or coated with a curable bonding agent such as filaments of glass, graphite, boron, or polyaramid (Kevlar™), either as individual strands or as multiple strand tows on the ribs  22  of the hard tooling  12 , the tows including multiple, parallel, elongated fibers either mutually laterally adhered by the bonding agent or maintained in place by transverse “warp” threads during the lay-up of the fiber material  200  (tows  1162 ) and the subsequent curing of the fiber material  200  including the fibers  202  and their coating  204  to form a composite structure. The profiled edge  26  on the consolidation block acts to control the placement and movement of the fiber material  200  and its coating, particularly during the curing thereof as the coating flows to assume the shape of the area present between the consolidation blocks  24  and the hard tooling  12 . Additionally illustrated is the cover  130  used during curing of the fiber material  200  to form the composite structure and a suitable resilient member  136  located between the cover  130  and the fiber material  200  formed on the ribs  22  of the hard tooling  12 . The resilient member  136  is used to confine and load the fiber material  200  during the curing thereof and in the area between the consolidation blocks  24  of the consolidation medium  14  and the ribs  22  of the hard tooling  12 . The resilient member  136  may be of any suitable resilient material for use in the curing of the fiber material at elevated temperatures to form the composite structure, such as synthetic rubber, neoprene, etc. Similarly, the resilient member  136  may have any suitable thickness for such use depending upon the composite structure being formed. As illustrated, the coating  204  has been substantially flowed from around the fibers  202  of the fiber material  200  during the curing process to take the shape of the area formed between the consolidation blocks  24 , the ribs  22  of the hard tooling  12 , and the resilient member  136  backed-up by cover  130 . In this manner, the profiled edges  26  of the consolidation blocks  24  act to control the placement of fibers  202  during formation and curing of the composite structure to provide accurate dimensional control of the composite structure formed. In this manner, dimensions may be precisely controlled for the composite structure and, more particularly, repeated to form additional composite structures using the hard tooling  12  and consolidation blocks  24  of the consolidation medium  14 . If desired, the resilient member  136  may be used without cover  130  during the curing of the composite structure if the member  136  has sufficient strength for such use without substantial deflection or movement thereof. 
     Referring to drawing FIG. 18, an alternative arrangement of a portion of a composite structure formed on hard tooling  12  or  112  (not shown) with consolidation blocks  24  and cover  130  is illustrated as depicted along lines  9 — 9  of drawing FIG.  16 . As illustrated, the consolidation blocks  24  have the edge  26  thereof having a suitable vertical profile adjacent the composite structure being formed on the ribs  22  of the hard tooling  12 . The edge  26  may be of any suitable shape and may vary from consolidation block  24  to adjacent consolidation block  24 , as illustrated. The purpose of the profiled edge  26  on the consolidation block  24  is to confine and retain the fiber material  200  which includes fibers  202  and coating material  204  thereon, either as individual strands or as multiple strand tows  1162  on the hard tooling  12 , during the lay-up of the fiber material  200  and the subsequent curing of the fiber material  200  including the fibers  202  and their coating  204  to form a composite structure. The profiled edge  26  on the consolidation block acts to control the placement and movement of the fiber material  200  and its coating, particularly during the curing thereof as the coating flows to assume the shape of the area present between the consolidation blocks  24  and the ribs  22  of the hard tooling  12 . Additionally illustrated is the cover  130  used during curing of the fiber material  200  to form the composite structure and a suitable resilient member  138  located between the cover  130  and the fiber material  200  formed on the ribs  22  of the hard tooling  12 . The resilient member  138  is an inflatable type member having a resilient cover  140  and inflation cavity  142  therein used to confine and load the fiber material  200  during the curing thereof and in the area between the consolidation blocks  24  and the ribs  22  of the hard tooling  12 . The resilient member  138  may be of any suitable resilient material for use in the curing of the fiber material at elevated temperatures to form the composite structure, such as synthetic rubber, neoprene, etc., capable of withstanding the inflation pressures used for loading of the fiber material  200  during the curing thereof. If formed to have sufficient strength, a suitable inflatable resilient member  138  may be used without a cover  130 . The inflatable member  138  may be inflated using any desired gas, such as air, nitrogen, etc. as desired. The inflation pressure in cavity  142  may be monitored remotely in real time during the curing process, if desired, to insure the proper application of pressure to the fiber material  200  during the curing thereof. Similarly, the resilient member  138  may have any suitable thickness for such use, depending upon the composite structure being formed. As illustrated, the coating  204  has been substantially flowed from around the fiber  202  of the fiber material  200  during the curing process to take the shape of the area formed between the consolidation blocks  24 , the ribs  22  of the hard tooling  12 , and the resilient member  138  backed-up by cover  130 . In this manner, the profiled edges  26  of the consolidation blocks  24  act to control the fiber  202  placement during formation and curing of the composite structure to provide accurate dimensional control of the composite structure formed. Dimensions may be precisely controlled for the composite structure and, more particularly, repeated to form additional composite structures using the hard tooling  12  and consolidation blocks  24 . 
     Referring to drawing FIG. 19, illustrated is a view of the cured composite structure formed by the fiber material  200  (of tows  1162 ) between hard tooling  12  or  112  (not shown) and the consolidation blocks  24 . As illustrated, the fibers  200  overlap each other at the intersection thereof with the coating material  204  being retained by and assuming the desired profile shape of the edges  26  of the consolidation blocks  24 . In this manner, precise control of the shape and dimensions of the composite structure being formed on the hard tooling  12  or  112  using consolidation blocks  24  is provided on a repeatable basis for forming multiple composite structures using the same hard tooling  12  or  112  and consolidation blocks  24 . 
     Referring to drawing FIG. 20 a portion of a composite structure formed on hard tooling  12 , or  112  (not shown), with consolidation blocks  24  and cover  130  is illustrated. The consolidation blocks  24  have edge  26  having a suitable vertical profile adjacent the composite structure being formed on hard tooling  12 . The edge  26  may be of any suitable shape and may vary from consolidation block  24  to adjacent consolidation block  24 , as illustrated. The purpose of the profile edge  26  on the consolidation block  24  is to confine and retain the fiber material  200  (tows  1162 ) which includes fiber  202  and coating material  204  thereon, either as individual strands or as multiple strand tows on the hard tooling  12  during the lay-up of the fiber material  200  and the subsequent curing of the fiber material  200  including the fibers  202  and their coating  204  to form a composite structure. The profiled edge  26  on the consolidation block  24  acts to control the placement and movement of the fiber material  200  and its containing, particularly during the curing thereof, as the coating flows to assume the shape of the area present between the consolidation blocks  24  and the ribs  22  of the hard tooling  12 . Additionally illustrated are multiple layers  206  of fibers  202  having a coating  208  thereon which are placed on the exterior of consolidation blocks  24  and the upper extent of the fibers  202  forming the ribs  210  of the composite structure while the layers  206  of fibers  202  form the shell or cover  212  of the composite structure. The layers  206  being placed over the ribs  210  after the formation thereof on the ribs  22  of the hard tooling  12  and over the consolidation blocks  24  on the hard tooling  12 . The resilient member  136  may be of any suitable resilient material for use in the curing of the fiber material at elevated temperatures to form the composite structure, such as synthetic rubber, neoprene, etc. Similarly, the resilient member  136  may have any suitable thickness for such use, depending upon the composite structure being formed. As illustrated, the coating  204  on fibers  202  has been substantially flowed from around the fibers  202  of the fiber material  200  during the curing process to take the shape of the area formed between the consolidation blocks  24 , the hard tooling  12 , and the resilient member  136  backed-up by cover  130 . In this manner, the profiled edges  26  of the consolidation blocks  24  act to control the placement of fibers  202  during formation and curing of the composite structure to provide accurate dimensional control of the composite structure formed. In this manner, dimensions may be precisely controlled for the composite structure and, more particularly, repeated to form additional composite structures using the hard tooling  12  and the consolidation blocks  24  of the consolidation medium  14  in conjunction with the consolidation of the layers  206  forming the shell or cover  212  of the composite structure while ribs  210  are formed between blocks  24 . If desired, the resilient member  136  may be used without cover  130  during the curing of the composite structure if the member  136  has sufficient strength for such use without substantial deflection or movement thereof. 
     Referring to drawing FIG. 21, a portion of a composite structure formed on hard tooling  12 , or  112  (not shown), with consolidation blocks  24  of consolidation medium  14  and cover  130  is illustrated. As illustrated, the hard tooling  12  has one or more layers  206  of fiber material  200  thereon prior to the consolidation blocks  24  being placed on the tooling  12 . If desired, the layers  206  of fiber material  200  are placed on the hard tooling  12  to form a cover or shell  212  followed by the placement of fiber material  200  thereon to form the ribs  210  on the cover or shell  212 . In one instance, the ribs  210  may be formed from individual strands or as multiple strand tows  1162  on the hard tooling  12  prior to the use of the consolidation blocks  24 . Alternately, after the consolidation blocks  24  are located on the hard tooling  12  after the application of the layers  206  thereon, the ribs  210  may be formed from individual strands or as multiple strand tows  1162  on the layers  206  on the hard tooling  12  in the area where blocks  24  are or are to be located. As previously described, the consolidation blocks  24  each have a suitable vertical profile adjacent the composite structure being formed between the consolidation blocks  24 , the purpose of the profiled edge  26  being to confine, control, and retain the fiber material  200  which includes fibers  202  and coating material  204  thereon during the lay-up of the fiber material  200  and the curing of the fiber material  200  to form a composite structure. A cover  130  is used during curing of the fiber material  200  to form the composite structure and a suitable resilient member  136  is located between the cover  130  and the fiber material  200  to confine and load the fiber material  200  during the curing thereof and in between and below the consolidation blocks  24 . The resilient member  136  may be of any suitable material and thickness for use in the curing of the fiber material  200 . As illustrated, the coating  204  has been substantially flowed from around the fibers  202  of the fiber material  200  during the curing process. 
     Referring to drawing FIG. 22, a portion of a composite structure formed on hard tooling  12 , or  112  (not shown), with consolidation blocks  24  of consolidation medium  14  and cover  130  is illustrated. As illustrated, the hard tooling  12  has one or more layers  206  of fiber material  200  thereon to form shell or cover  212  while layers of fiber material  200 , tows  1162 , are placed thereon to form ribs  210  prior to the consolidation blocks  24  being placed on shell or cover  212  and are placed between ribs  210 . The fiber material  200  is placed on the hard tooling  12  to form the cover or shell  212  followed by the placement of the fiber material  200 , tows  1162 , on the cover or shell  212  to form the ribs  210  of the composite structure. Subsequently, a flexible, resilient sheet  160  having consolidation blocks  24  attached thereto, the consolidation medium, is used to insert or locate the consolidation blocks  24  between ribs  210  prior to the curing of the fiber material  200 . The consolidation blocks may be secured by any suitable means to the flexible, resilient sheet  160 , such as by an adhesive  162  or by the pin or nub  30  of consolidation block  24  mating with an aperture  164  in the sheet  160 . The flexible, resilient member having sufficient flexibility and resiliency to allow positioning of the consolidation blocks  24  into the areas between the ribs  210  formed on the fiber material  200  on the hard tooling  12 . The consolidation blocks  24  have a vertical profile  26  thereon adjacent the composite structure, such as a rib  210 , being formed between the consolidation blocks  24  to control the fiber material during the curing thereof. A cover  130  is used during the curing of the fiber material  200  to form a composite structure and a suitable resilient member  136  is located between the flexible, resilient sheet  160  retaining consolidation blocks  24  thereon and the cover  130  to confine and load the fiber material  200  during the curing thereof. The resilient member  136  may be of any suitable material and thickness for use in the curing of the fiber material  200 . As illustrated, the coating material  204  on the fiber material  200  has been substantially flowed from around the fibers  202  during the curing process. 
     Referring to drawing FIG. 23, a portion of a composite structure on hard tooling  12 , or  112  (not shown), with consolidation blocks  24  of consolidation medium  14  and cover  130  is illustrated. As illustrated, the hard tooling  12  has one or more layers  206  of fiber material  200  thereon to form shell or cover  212  while layers of fiber material  200 , tows  1162 , are placed thereon to form ribs  210  prior to the consolidation blocks  24  being placed on the hard tooling  12  to form the cover or shell  212  and are placed between ribs  210 . Subsequently, a flexible, resilient sheet or member  170  having chamber  176  and apertures  174  therein and having consolidation blocks  24  attached thereto, the consolidation medium, is used to insert or locate the consolidation blocks  24  between the ribs  210  prior to the curing of the fiber material  200 . The consolidation blocks  24  may be secured by any suitable means to the flexible, resilient sheet  170 , such as by adhesive  172  or the pin or nub  30  of consolidation block  24  mating with an aperture  174  in the sheet  170 . The member  170  has chamber  176  therein connected to aperture  300  in cover  130  to allow for the application of fluid pressure to the member  170  either to help facilitate the insertion of the consolidation blocks  24  between the ribs  210  or for the application of pressure during the curing process of the fiber material  200 , or both. Any suitable fluid may be used in the cavity  176 , such as compressed air, inert gas, etc. The flexible, resilient member  170  has sufficient flexibility and resiliency to allow positioning of the consolidation blocks  24  into the areas between the ribs  210  formed on the fiber material  200  forming the shell or cover  210  on the hard tooling  12 . The consolidation blocks  24  having a vertical profile  26  adjacent the composite structure, such as a rib  210 , being formed between the consolidation blocks  24  to control the fiber material during the curing thereof. A cover  130  is used in addition to the member  170  during the curing of the fiber material  200  to form a composite structure. The resilient member  170  may be of any suitable material and thickness to confine and load the fiber material  200  during the curing thereof. As illustrated, the coating material  204  on the fiber material  200  has been substantially flowed from around the fibers  202  during the curing process. 
     Referring to drawing FIG. 24, a portion of a composite structure formed on hard tooling  12  or  112  (not shown) with flexible, resilient mold member  180  of the consolidation medium  14  is illustrated. As illustrated, a rib  210  is formed of tows  1162  on hard tooling  12  of fiber material  200  of fibers  202  having coating  204  thereon. The member  180 , the consolidation medium, is formed of flexible, resilient material having a predetermined configuration or shape desired for the curing of the fiber material  200  located on hard tooling  12 . The member  180  may be of any suitable material for use in the curing of the fiber material  200 , such material having sufficient strength to retain its shape during the curing process and confine the fiber material  200  forming a rib  210  or the like of the composite structure during curing as well as sufficient resiliency to allow the insertion of the member  180  into the areas between ribs  210  formed on the hard tooling  12 . The member  180  may be a silicon elastomeric material, rubber, synthetic rubber, neoprene, etc. reinforced with a suitable fabric material, such as nylon, Kevlar™, metal, etc. The member  180  may be formed into the desired shape, such as by compression molding. The member  180  may have the portions  182  having profile  186  thereon used to confine the fiber material  200  forming the ribs  210  of the composite structure having any desired profile either vertically or cross-sectionally, as desired, to yield the desired rib structure  210  after curing. The member  180  is applied or installed on the hard tooling  12  after the application of the fiber material  200  to form the uncured rib  210  on the hard tooling  12 . The member  180  is applied to the hard tooling over the ribs  210  of fiber material  200  formed thereon with the portions  182  of the member  180  applied over the ribs  210  and with the remaining portions of the member  180  abutting the hard tooling  12 . During the curing process of the fiber material  200 , the member  180  is loaded to compress the fiber material  200  by the application of a suitable amount of pressure, such as compressed air or an inert gas, through aperture  300  in cover  130  into the area  142  between the cover  130  and member  180  to compress the member  180  about the rib  210  during curing and against hard tooling  12  to control the shape of the rib  210  during curing and the flow of coating material  204  on the fibers  202  during the curing process with the profile  186  on the portion  182  providing the cross-sectional shape control of the rib  210 . As previously described, the fiber material  200  may be applied as individual strands or as tows  1162  of strands to form the rib  210  on the hard tooling  12 . As illustrated, the profile  186  of portion  182  of the member  180  forms a rib  210  during curing having a cross-sectional shape similar to that when consolidation blocs  24  are used during the curing process. 
     Referring to drawing FIG. 25, a portion of a composite structure formed on hard tooling  12  or  112  (not shown) with flexible, resilient mold member  180  of the consolidation medium  14  is illustrated. As illustrated, a rib  210  is formed on rib  22  of hard tooling  12  being formed of tows  1162  on hard tooling  12  of fiber material  200  of fibers  202  having coating  204  thereon. The member  180 , the consolidation medium, is formed of flexible, resilient material having a predetermined configuration or shape desired for the curing of the fiber material  200  located on the ribs  22  of the hard tooling  12 . The member  180  may be of any suitable material for use in the curing of the fiber material  200 , such material having sufficient strength to retain its shape during the curing process and confine the fiber material  200  forming a rib  210  or the like of the composite structure during curing as well as sufficient resiliency to allow the insertion of the member  180  into the areas between ribs  210  formed on the hard tooling  12 . The member  180  may be a silicon elastomeric material, rubber, synthetic rubber, neoprene, etc. reinforced with a suitable fabric material, such as nylon, Kevlar™, metal, etc. The member  180  may be formed into the desired shape, such as by compression molding. The member  180  may have the portions  182  having profile  186  thereon used to confine the fiber material  200  forming the ribs  210  of the composite structure having any desired profile either vertically or cross-sectionally, as desired, to yield the desired rib structure  210  after curing. The member  180  is applied or installed on the hard tooling  12  after the application of the fiber material  200  to form the un-cured rib  210  on the hard tooling  12 . The member  180  is applied to the hard tooling  12  over the ribs  210  of fiber material  200  formed thereon with the portions  182  of the member  180  applied over the ribs  210  and with the remaining portions of the member  180  abutting the hard tooling  12 . During the curing process of the fiber material  200 , the member  180  is loaded to compress the fiber material  200  by the application of a suitable amount of pressure, such as compressed air or an inert gas, through aperture  300  in cover  130  into the area  142  between the cover  130  and member  180  to compress the member  180  about the rib  210  during curing and against hard tooling  12  to control the shape of the rib  210  during curing and the flow of coating material  204  on the fibers  202  during the curing process with the profile  186  on the portion  182  providing the cross-sectional shape control of the rib  210 . As previously described, the fiber material  200  may be applied as individual strands or as tows  1162  of strands to form the rib  210  on the hard tooling  12 . As illustrated, the profile  186  of portion  182  of the member  180  forms a rib  210  during curing having a cross-sectional shape similar to that when consolidation blocks  24  are used during the curing process. 
     Referring to drawing FIG. 26, a portion of a composite structure formed on hard tooling  12 , or  112  (not shown), with flexible, resilient mold member  180  of the consolidation medium  14  is illustrated. As illustrated, a cover or shell  212  of fiber material  200  is formed on hard tooling  12  prior to the rib  210  of fiber material  200 , tows  1162 , being formed on the hard tooling  12 . After the cover or shell  212  and rib  210  of fiber material  200  is formed, the flexible, resilient member  180  having portion  182  having profile  186  is installed over ribs  210  and cover or shell  212  prior to the curing of the fiber material  200 . The member  180 , the consolidation medium, is loaded by suitable pressure, such as air pressure or inert fluid pressure, through aperture  300  in cover  130  into the area  142  between the cover  130  and member  180  to compress the member  180  about the rib  210  and against cover or shell  212  during curing and against hard tooling  12  to control the shape of the cover  212  and rib  210  of the composite structure. As previously described, the fiber material  200  may be applied in sheets for cover or shell  212  and applied as individual strands or tows of strands to form the rib  210  on hard tooling  12 . 
     Referring to drawing FIG. 27, a portion of the flexible, resilient member  180  of the consolidation medium  14  is illustrated. The member  180  includes portions  182  having profiles  182 ,  182 ′ ( 182 ′ being located parallel the rotational axis  25  of hard tooling  12 / 112 ) thereon which cover ribs  210  during the curing process and recessed portions  182 , having side wall  186  as a portion thereon, which extend between the ribs  210 , the portions  182  contacting hard tooling  12  or fiber material  200 , tows  1162 , on the hard tooling  12  during the curing process of the fiber material  200 . The member  180  may be formed in a substantially flat sheet or any desired shape, such as cylindrical, annular, conical, etc. 
     Referring to drawing FIG. 28, a portion of a composite structure formed on hard tooling  12 , or  112  (not shown), with consolidation blocks  24  of the consolidation medium  14  and cover  130  is illustrated. The consolidation blocks  24  have edge  26  having a suitable profile adjacent the composite structure being formed therebetween on hard tooling  12 . The edge  26  may be of any suitable shape and may vary from consolidation block  24  to adjacent consolidation block  24 , as illustrated. The purpose of the profile edge  26  on the consolidation block  24  is to confine and retain the fiber material  200 , tows  1162 , which includes fiber  202  and coating material  204  thereon, either as individual strands or as multiple strand tows on the hard tooling  12  during the lay-up or curing or both of the fiber material  200 , tows  1162 , to form the composite structure. Additionally illustrated are multiple layers  206  of fibers  202  having coating  208  thereon which are placed, initially, on the hard tooling  12  to form an inner shell or cover  212  before the layers  202  forming ribs  210  thereover and, subsequently having multiple layers  206  formed on the ribs  210  after the formation thereof to form an outer cover or shell  212 . The consolidation blocks  24  may be placed on layer  206  before the formation of the ribs  210  or placed in between the ribs  210  after their formation on layers  206  on hard tooling  12  but before the curing of the fiber material. The consolidation blocks  24  remain in the cured composite structure to provide rigidity and strength thereto as well as control the curing of the covers or shells  212  as well as the ribs  210  during the curing of the fiber material  200 . The resilient member  136  may be of any suitable resilient material for use in the curing of the fiber material at elevated temperatures to form the composite structure, such as synthetic rubber, neoprene, etc. As illustrated, the coating  204  on fibers  202  has been substantially flowed around the fibers  202  of fiber material  200  during the curing process to take the shape of the area formed between the consolidation blocks  24 , the hard tooling  12 , and the resilient member  136  backed-up by cover  130 . In this manner, the profiled edges  26  of the consolidation blocks act to control the placement and/or movement of fibers during formation and curing of the composite structure to provide accurate dimensional control of the composite structure. 
     Referring to drawing FIGS. 1 through 28, to form the desired composite structure, the hard tooling  12  or  112  is formed having the desired recessed pockets  18  or  118  formed therein, apertures  20  formed therein, and ribs  22  or  122  formed between recessed pockets  18  or  118 . The desired shape consolidation blocks  24  of the consolidation medium  14  having the desired profiled edges  26  thereon are formed to mate with the corresponding recessed pockets  18  or  118  of the hard tooling  12  or  112  to form the desired composite structure. The consolidation blocks  24  may be retained within apertures  20  by any suitable apparatus as described herein. A mating piece to tooling  42  is formed with recessed pocket  48  therein and ribs  44  thereon to mate with the consolidation blocks  24  and hard tooling  12 . Alternately, a cover  130  is formed to mate with hard tooling  112  as well as a resilient member  136  or  138 . If the consolidation blocks  24  are not used during curing of the fiber material, the flexible, resilient member  170  or  180  or a flexible, resilient sheet  160  having consolidation blocks  24  thereon may be used to consolidate the fiber material. 
     After the hard tooling  12  or  112  has been assembled having the desired consolidation blocks  24  thereon, fiber material  200  is placed or applied in the area formed between the ribs  22  or  122  on hard tooling  12  or  112 , respectively, and the adjacent consolidation blocks  24  to form the composite structure. The fiber material may be placed in such areas using suitable equipment and apparatus and methods known in the industry as desired by placing individual, coated fibers or multi-strand fiber tows of fiber material  200  either continuously or in discreet length segments. 
     After the desired amount of fiber material  200  has been applied to the hard tooling  12  or  112  between the consolidation blocks  24 , the hard tooling  12  and the consolidation blocks  24  are covered with tooling  42 . Alternately, the fiber material  200  forming ribs  210  or ribs  210  and cover or shell  212  is covered with a resilient material  136  or  138  and, if desired, a cover  130  for the curing of the fiber material  200  at elevated temperatures to form the composite structure. After curing of the fiber material  200  to form the composite structure, the cover  130  and resilient member  136  or  138  is removed from the hard tooling  12  or  112  and consolidation blocks  24 . If necessary because of the shape of the profiled edge  26  on the consolidation blocks  24 , the blocks  24  may be removed next, leaving the composite structure on the hard tooling  12  or  112  for subsequent removal therefrom. If the composite structure is in annular form, such as illustrated in drawing FIGS. 7 and 8, the cover  130  is removed and the hard tooling  112  is removed from the interior of the annular composite structure by disassembling the hard tooling for removal from the structure. Alternately, the cover or shell  212  is formed on hard tooling  12  or  112  from fiber material in sheet form with the ribs  210  being formed thereon from fiber material  200 . The fiber material  200  is cured using flexible, resilient member  160  or  180  to control the fiber material during curing. 
     The use of the present invention of hard tooling  12  or  112 , the consolidation blocks  24 , resilient member  136  or  138 , the flexible, resilient member  160 ,  170 ,  180 , and if desired, cover  130  allows the repeated manufacture of desired composite structures having the desired dimensions thereof, thereby producing a composite structure with minimal variations therein. 
     The hard tooling  12  or  112  in conjunction with the consolidation blocks  24 , which are retained precisely within recessed pockets  18  or  188  of the hard tooling  12  or  112  or on the flexible, resilient member  160  or  170  or the flexible, resilient member  180  molded to the desired composite structure shape, respectively, provides for precise dimensional control of the composite structure being formed with minimal variations therein. The hard tooling  12  or  112 , consolidation blocks  24 , flexible, resilient member  160 , and flexible, resilient member  170  or  180  may be formed in any desired configuration to form any desired composite structure having any desired shape, such as flat, annular, cylindrical, etc. 
     Those skilled in the art will recognize changes, additions, and deletions to and variations of the hard tooling, consolidation blocks, resilient members, and covers illustrated herein that are within the scope and the teachings of the invention. Such are covered within the scope of the claimed invention.