Abstract: A thermoplastic composite component assembly and method of manufacturing the thermoplastic composite component assembly is disclosed. The thermoplastic composite component assembly is manufactured by first performing a molding step to form individual assembly features as discrete assembly feature components, and separately forming a thermoplastic composite component using a first compression molding step. Then, a reprocessing step is performed where the discrete assembly feature components are integrated with the thermoplastic composite component using a second compression molding step. The reprocessing step essentially “welds” the discrete assembly feature components to the thermoplastic composite component at each of a plurality of desired assembly feature sites.

Abstract: A thermoplastic composite component assembly and method of manufacturing the thermoplastic composite component assembly is disclosed. The thermoplastic composite component assembly is manufactured by first performing a molding step to form individual assembly features as discrete assembly feature components, and separately forming a thermoplastic composite component using a first compression molding step. Then, a reprocessing step is performed where the discrete assembly feature components are integrated with the thermoplastic composite component using a second compression molding step. The reprocessing step essentially “welds” the discrete assembly feature components to the thermoplastic composite component at each of a plurality of desired assembly feature sites.

Abstract: Systems and processes that limit distortion of inserts (e.g., previously formed parts) in insert molding and overmolding processes. Initially, a mold may be closed (e.g., clamped) about an insert with the mold at a first temperature. After closing the mold about the insert, the mold is heated up to a second temperature (e.g., a temperature suitable for injection of the molding material) and filled with the molding material to contact (e.g., encapsulate) the insert. After the mold has been cooled, the mold may be opened and the finished part (including the insert and the solidified molding material) removed (e.g., ejected). The process may be repeated for additional finished parts. Closing the mold about the insert before heating the mold to the injection temperature advantageously limits distortion of the insert that would otherwise occur by placing the insert into the mold with the mold already at the injection temperature.

Abstract: Systems and processes that limit distortion of inserts (e.g., previously formed parts) in insert molding and overmolding processes. Initially, a mold may be closed (e.g., clamped) about an insert with the mold at a first temperature. After closing the mold about the insert, the mold is heated up to a second temperature (e.g., a temperature suitable for injection of the molding material) and filled with the molding material to contact (e.g., encapsulate) the insert. After the mold has been cooled, the mold may be opened and the finished part (including the insert and the solidified molding material) removed (e.g., ejected). The process may be repeated for additional finished parts. Closing the mold about the insert before heating the mold to the injection temperature advantageously limits distortion of the insert that would otherwise occur by placing the insert into the mold with the mold already at the injection temperature.