Abstract: An apparatus and method are provided for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinal collar that defines a cavity and a rigid inner support structure extending longitudinally in the cavity. The collar and/or the inner support structure define a mold contour. One or more heaters are configured to heat at least a formation portion of the duct to a formation temperature. An expansion member, such as an expandable elastomer, which is disposed between an inner surface of the collar and an outer surface of the inner support structure, is configured to urge the formation portion of the duct against the mold contour to thermoplastically form the duct.

Abstract: An apparatus and method are provided for circumferentially measuring cross-sectional characteristics of a tubular member. The apparatus includes first and second template members that cooperably define an aperture for receiving the tubular member. At least one of the template members is adjustable so that the aperture can be adjusted between open and closed positions. A measurement device can be configured to detect the relative position of the first and second template members, thereby measuring the relative adjustment of the members between the open and closed positions. This measurement is indicative of the cross-sectional size of the tubular member, e.g., for determining the diameter of the tubular member. Alternatively, multiple measurement devices can respond to a contact force between the measurement devices and the tubular member, e.g., to determine a variation in wall thickness of the tubular member.

Abstract: An apparatus and method are provided for thermoplastically forming a contour in a thermoplastic duct defining a passage. The apparatus includes a longitudinal collar that defines a cavity and a rigid inner support structure extending longitudinally in the cavity. The collar and/or the inner support structure define a mold contour. One or more heaters are configured to heat at least a formation portion of the duct to a formation temperature. An expansion member, such as an expandable elastomer, which is disposed between an inner surface of the collar and an outer surface of the inner support structure, is configured to urge the formation portion of the duct against the mold contour to thermoplastically form the duct.