Abstract: A system for joining a first thermoplastic component of a workpiece with a second thermoplastic component of the workpiece includes a first joining plate assembly comprising a housing, a heat plate, and a thermal insulator disposed between the housing and the heat plate, wherein the heat plate defines a heating surface; a second joining plate assembly opposed from the first joining plate assembly; and a clamping assembly engaged with both the first joining plate assembly and the second joining plate assembly.

Abstract: A joining system includes a holding fixture assembly configured to hold a fuselage skin. The stringers are temporarily attached to the fuselage skin. The joining system includes an upper beam assembly including an upper beam and a lower beam assembly. The lower beam assembly includes a lower beam and at least one lower heating element. The holding fixture assembly is coupled to the upper beam assembly. The holding fixture assembly is coupled to the lower beam assembly. The upper beam is movable relative to the lower beam to clamp the at least one of the plurality of stringers and the fuselage skin together prior to and during welding.

Abstract: A system for manufacturing a part includes a mold having a contoured forming surface. The system also includes at least one tension strap, configured to attach to a consolidated laminate sheet, and a heating assembly, positioned relative to the mold and configured to supply heat to the consolidated laminate sheet, when attached to the at least one tension strap, to form a heated consolidated laminate sheet. The system additionally includes a strap retraction mechanism, configured to retract the at least one tension strap, when attached to the consolidated laminate sheet, to force the heated consolidated laminate sheet against the contoured forming surface of the mold. The heating assembly includes a flexible heating element configured to flex to conform to a shape of the heated consolidated laminate sheet as the heated consolidated laminate sheet is forced against the contoured forming surface of the mold.

Abstract: A system for manufacturing a part that includes a mold, a first fixation component, fixed to the mold, second fixation components, each configured to be fixed to a consolidated laminate sheet, third fixation components, each fixed to the mold. The system also includes tension straps. The first fixation component is configured to attach the consolidated laminate sheet to the mold so that the consolidated laminate sheet does not translationally move relative to the forming surface of the mold. Each one of the second fixation components is configured to attach the tension straps to the consolidated laminate sheet. Each one of the third fixation components is configured to attach the tension straps to the mold so that the tension straps are movable relative to the mold. The system also includes a heating assembly and a strap retraction mechanism, configured to retract the tension strap.

Abstract: A joining system includes a holding fixture assembly configured to hold a fuselage skin. The stringers are temporarily attached to the fuselage skin. The joining system includes an upper beam assembly including an upper beam and a lower beam assembly. The lower beam assembly includes a lower beam and at least one lower heating element. The holding fixture assembly is coupled to the upper beam assembly. The holding fixture assembly is coupled to the lower beam assembly. The upper beam is movable relative to the lower beam to clamp the at least one of the plurality of stringers and the fuselage skin together prior to and during welding.

Abstract: Disclosed herein are systems and methods for manufacturing a part. An example method comprises heating a consolidated laminate sheet, comprising multiple plies each made of fibers embedded in a thermoplastic resin, to a heated temperature below a melting temperature of the thermoplastic resin to form a heated consolidated laminate sheet. The method also comprises forcing the heated consolidated laminate sheet against a contoured forming surface of a mold until a shape of the heated consolidated laminate sheet corresponds with a contoured shape of the contoured forming surface of the mold.