Abstract: Apparatus and methods for providing airflow within an aircraft are disclosed. In one embodiment, a method includes forming a clamshell component, including: providing first and second spaced-apart mold members; forming first and second half-body portions, including forming at least one sheet of formable material between the first and second mold members; and coupling the first and second half-body portions to form the clamshell component. The method also includes coupling the clamshell component to a source of air; and operating the source of air to provide an airflow through the clamshell component.

Abstract: A duct formed of a thermoplastic material is lightweight, strong, flame and smoke resistant, and non-toxic. The duct is formed from a flat laminate and does not require a specialized, disposable mandrel for supporting conventional thermoset plies. Preferably, the duct is formed from a preform, which is cut according to the desired shape and size of the duct so that trimming after the duct has been formed is not required. Additionally, features such as holes and spud locations can be provided by cutting or marking the preform before forming the duct. Each duct can be formed of multiple articulated segments that are joined by connectors.

Abstract: Apparatus and methods for forming thermoplastic clamshell components are disclosed. In one embodiment, a method includes providing first and second spaced-apart mold members. Next, first and second half-body portions are formed by a process including forming at least one sheet of formable material between the first and second mold members. The first and second half-body portions are then coupled to form the clamshell component. In alternate embodiments, the coupling of the first and second half-body portions may include forming the flange portions between a pair of heated members, or crimping or welding the flange portions.

Abstract: There is provided a duct and an associated preform and method. The duct is formed of a thermoplastic material and is lightweight, strong, flame and smoke resistant, and non-toxic. The duct is formed from a flat laminate and does not require a specialized, disposable mandrel for supporting conventional thermoset plies. Preferably, the duct is formed from a preform, which is cut according to the desired shape and size of the duct so that trimming after the duct has been formed is not required. Additionally, features such as holes and spud locations can be provided by cutting or marking the preform before forming the duct. Each duct can be formed of multiple articulated segments that are joined by connectors.