Abstract: Disclosed herein is a composite sandwich panel that includes a first face portion with fully consolidated comingled first fibers and a first thermoplastic matrix. The composite sandwich panel also includes a second face portion with fully consolidated comingled second fibers and a second thermoplastic matrix. Additionally, the composite sandwich panel includes at least one core portion with partially consolidated comingled third fibers and a third thermoplastic matrix. The at least one core portion is interposed between the first and second face portions. The first thermoplastic matrix is melded with the third thermoplastic matrix and the second thermoplastic matrix is melded with the third thermoplastic. A density of the fibers across a thickness of the composite panel is non-uniform.

Abstract: A system and method combine ablation of a surface of a part with inspection of the internal integrity of the part. A laser may direct an ablative laser pulse at the surface of the part sufficient to remove a portion of material from the part surface and to cause the part to produce an ultrasound waveform. A positioning system may provide relative movement of the ablative laser pulse and the part for application of a series of ablative laser pulses at a series of locations over an area of the surface of the part. An ultrasonic detection device may couple to the part to receive the ultrasound waveform and transmit it to a part inspection system that has stored a set of reference waveforms in a control computer. The system compares the ultrasound waveform to one or more of the reference waveforms to detect and characterize anomalies in the part.

Abstract: Provided are molds, comprising non-metal base portions and protective optical layers that cover and shield these base portions from laser ablation. For example, a protective optical layer may reflect a laser beam used for ablating the mold. Methods of forming these protective optical layers on non-metal base portions are also provided. In some embodiments, this protective optical layer is the outermost layer exposed to the environment. Alternatively, the protective optical layer may be covered by a release layer. The release layer may be retained or removed during laser ablation. In some embodiments, light emitted by a mold during laser ablation is analyzed to determine performance of its protective optical layer. This feedback may be used to control the laser ablation such as to control orientation of the laser beam relative to the mold.

Abstract: Disclosed herein is a composite sandwich panel that includes a first face portion with fully consolidated comingled first fibers and a first thermoplastic matrix. The composite sandwich panel also includes a second face portion with fully consolidated comingled second fibers and a second thermoplastic matrix. Additionally, the composite sandwich panel includes at least one core portion with partially consolidated comingled third fibers and a third thermoplastic matrix. The at least one core portion is interposed between the first and second face portions. The first thermoplastic matrix is melded with the third thermoplastic matrix and the second thermoplastic matrix is melded with the third thermoplastic. A density of the fibers across a thickness of the composite panel is non-uniform.

Abstract: Disclosed herein is a composite sandwich panel that includes a first face portion with fully consolidated comingled first fibers and a first thermoplastic matrix. The composite sandwich panel also includes a second face portion with fully consolidated comingled second fibers and a second thermoplastic matrix. Additionally, the composite sandwich panel includes at least one core portion with partially consolidated comingled third fibers and a third thermoplastic matrix. The at least one core portion is interposed between the first and second face portions. The first thermoplastic matrix is melded with the third thermoplastic matrix and the second thermoplastic matrix is melded with the third thermoplastic. A density of the fibers across a thickness of the composite panel is non-uniform.

Abstract: A system and method combine ablation of a surface of a part with inspection of the internal integrity of the part. A laser may direct an ablative laser pulse at the surface of the part sufficient to remove a portion of material from the part surface and to cause the part to produce an ultrasound waveform. A positioning system may provide relative movement of the ablative laser pulse and the part for application of a series of ablative laser pulses at a series of locations over an area of the surface of the part. An ultrasonic detection device may couple to the part to receive the ultrasound waveform and transmit it to a part inspection system that has stored a set of reference waveforms in a control computer. The system compares the ultrasound waveform to one or more of the reference waveforms to detect and characterize anomalies in the part.

Abstract: Provided are molds, comprising non-metal base portions and protective optical layers that cover and shield these base portions from laser ablation. For example, a protective optical layer may reflect a laser beam used for ablating the mold. Methods of forming these protective optical layers on non-metal base portions are also provided. In some embodiments, this protective optical layer is the outermost layer exposed to the environment. Alternatively, the protective optical layer may be covered by a release layer. The release layer may be retained or removed during laser ablation. In some embodiments, light emitted by a mold during laser ablation is analyzed to determine performance of its protective optical layer. This feedback may be used to control the laser ablation such as to control orientation of the laser beam relative to the mold.

Abstract: Provided are methods for cleaning processing tools from residue using laser ablation. Also provided are processing tools comprising non-metal base portions and protective optical layers that cover and shield these base portions from laser ablation. For example, a protective optical layer may reflect a laser beam used for ablating the tool. Methods of forming these protective optical layers on non-metal base portions are also provided. In some embodiments, this protective optical layer is the outermost layer exposed to the environment. Alternatively, the protective optical layer may be covered by a release layer. The release layer may be retained or removed during laser ablation. In some embodiments, light emitted by a processing tool during laser ablation is analyzed to determine performance of its protective optical layer. This feedback may be used to control the laser ablation such as to control orientation of the laser beam relative to the processing tool.

Abstract: Provided are methods for cleaning processing tools from residue using laser ablation. Also provided are processing tools comprising non-metal base portions and protective optical layers that cover and shield these base portions from laser ablation. For example, a protective optical layer may reflect a laser beam used for ablating the tool. Methods of forming these protective optical layers on non-metal base portions are also provided. In some embodiments, this protective optical layer is the outermost layer exposed to the environment. Alternatively, the protective optical layer may be covered by a release layer. The release layer may be retained or removed during laser ablation. In some embodiments, light emitted by a processing tool during laser ablation is analyzed to determine performance of its protective optical layer. This feedback may be used to control the laser ablation such as to control orientation of the laser beam relative to the processing tool.

Abstract: Disclosed herein is a composite sandwich panel that includes a first face portion with fully consolidated comingled first fibers and a first thermoplastic matrix. The composite sandwich panel also includes a second face portion with fully consolidated comingled second fibers and a second thermoplastic matrix. Additionally, the composite sandwich panel includes at least one core portion with partially consolidated comingled third fibers and a third thermoplastic matrix. The at least one core portion is interposed between the first and second face portions. The first thermoplastic matrix is melded with the third thermoplastic matrix and the second thermoplastic matrix is melded with the third thermoplastic. A density of the fibers across a thickness of the composite panel is non-uniform.