Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.

Abstract: Apparatus and methods for providing airflow within an aircraft are disclosed. In one embodiment, a method includes forming a clamshell component, including: providing first and second spaced-apart mold members; forming first and second half-body portions, including forming at least one sheet of formable material between the first and second mold members; and coupling the first and second half-body portions to form the clamshell component. The method also includes coupling the clamshell component to a source of air; and operating the source of air to provide an airflow through the clamshell component.

Abstract: There are provided apparatuses and related methods for preforming sheets to form preforms for forming ducts. The preforms can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape of the duct. For example, rollers, rods, tubes, or a funnel can be used to bend the sheet.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.

Abstract: Apparatus and methods for forming thermoplastic clamshell components are disclosed. In one embodiment, a method includes providing first and second spaced-apart mold members. Next, first and second half-body portions are formed by a process including forming at least one sheet of formable material between the first and second mold members. The first and second half-body portions are then coupled to form the clamshell component. In alternate embodiments, the coupling of the first and second half-body portions may include forming the flange portions between a pair of heated members, or crimping or welding the flange portions.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.