Abstract: Embodiments of the present invention relate to an apparatus and method for induction fusing of thermoplastic composite materials using a film of pressurized air to provide active cooling as well as consolidation pressure. The invention may be employed to weld multiple pre-consolidated thermoplastic composite laminates or to form a single laminate from individual plies of thermoplastic composite material.

Abstract: Embodiments of the present invention relate to a system and method for consolidating a thermoplastic composite component in situ within a thermoplastic composite deposition cell by means of heat and pressure. Heat may be applied to the thermoplastic composite component by means of an induction coil. Pressure may be applied to the thermoplastic composite component by means of a pressure applicator. An independent means may be provided for reacting at least a portion of the force directed to the pressure applicator. Consolidation may be performed in parallel with deposition within the same work cell.

Abstract: Embodiments of the present invention relate to a thermoplastic composite broadgood and a means of depositing a thermoplastic composite broadgood onto a mold. The broadgood may comprise of a plurality of separate, parallel strips of thermoplastic prepreg attached together by a plurality of delamination arresting elements. The broadgood may be deposited onto a mold by means of an apparatus comprising a plurality of flexible metal straps, each strap being configured to be heated. The straps may temporarily adhere to the broadgood when heated, thereby allowing the broadgood to be moved by means of the apparatus.