Abstract: A technique is provided for forming an article having a sharp, detailed edge by thermoforming thermoplastic resin prepregs containing randomly arranged reinforcing fibers and ordered, substantially continuous reinforcing fibers. The thermoforming mold used for this technique has a mold cavity with a wedge-shaped interior portion and a mold plug with a wedge-shaped exterior portion wherein the mold plug is capable of applying additional pressure along its edge section. The randomly arranged reinforcing fibers are utilized to form the sharp edge portion of the resulting article while the ordered, substantially continuous reinforcing fibers are utilized to form the remaining wall portions of the resulting article.

Abstract: A technique is provided for both forming frame portions from thermoplastic resin prepregs containing randomly arranged reinforcing fibers directly at predetermined location(s) upon a preformed wall portion and simultaneously bonding such as formed frame portions directly to such wall portion at such location(s). The wall portion is itself a laminate derived from thermoplastic resin prepregs containing ordered, substantially continuous reinforcing fibers.

Abstract: A technique is provided for both forming frame portions from thermoplastic resin prepregs containing randomly arranged reinforcing fibers directly at predetermined location(s) upon a preformed wall portion and simultaneously bonding such as formed frame portions directly to such wall portion at such location(s). The wall portion is itself a laminate derived from thermoplastic resin prepregs containing ordered, substantially continuous reinforcing fibers.

Abstract: A forced jet convection oven is utilized to practice a vacuum bagging process for the production of thermoplastic composite laminates containing reinforcing fiber. The oven comprises a support suitable for supporting a panel wherein said support means is positioned in the oven with the upper surface of the support means being spaced apart from the oven ceiling to define a panel-receiving chamber between the upper surface of the support means and the oven ceiling, a first manifold means having a first multiplicity of outlets directed toward the upper surface of the support means wherein said first manifold means is positioned between the upper surface of the support means and the oven ceiling; and a second manifold means having a second multiplicity of outlets directed toward the upper surface of the support means wherein said second manifold means is positioned between the upper surface of the support means and the oven floor.

Abstract: A technique is provided for both forming frame portions from thermoplastic resin prepregs containing randomly arranged reinforcing fibers directly at predetermined location(s) upon a preformed wall portion and simultaneously bonding such as formed frame portions directly to such wall portion at such location(s). The wall portion is itself a laminate derived from thermoplastic resin prepregs containing ordered, substantially continuous reinforcing fibers.