Abstract: A method for joining functional components with at least a thermoplastic components to thermosetting composites with at least some thermoplastic surface. The thermosetting composite has a functional thermoplastic surface layer attached by a process of selection of a compatible thermoplastic, heating the combined materials to allow migration of uncured thermosetting polymer into the thermoplastic polymer, then cooling the combined materials to provide a strongly attached thermoplastic surface. The thermosetting composite component may have a polymeric material coating. The present invention subsequently relates to the joining of the functional component and thermosetting polymer composite components, using high-speed oscillating relative displacement or high-speed continuous relative displacement.

Abstract: A method of precision surface re-profiling of a composite polymeric component comprising a region capable of being re-profiled, comprising the steps of locating the polymeric composite component with a formable surface relative to a supporting fixture, the thickness of component comprising the formable surface being greater than the desired final thickness in a region to be re-profiled, moving a forming head into position into contact with the formable surface of the composite component with the aid of precision location or measurement sensors, causing the formable surface of the component to flow under the tool and creating a precisely defined local thickness or profile of component under the forming tool, and moving the forming head along the region of the component to be re-profiled, while maintaining the forming tool at a predetermined height profile or while leaving the re-profiled component with a predetermined thickness profile.