Abstract: There is provided an over-molded thermoplastic composite part having an over-molded color, and including a consolidated thermoplastic composite laminate formed by a consolidation process. The consolidated thermoplastic composite laminate is made of a laminate polymer material. The over-molded thermoplastic composite part further includes an over-mold layer over-molded, via an over-molding process, over a first side of the consolidated thermoplastic composite laminate. The over-mold layer includes an over-mold mixture of an over-mold polymer material mixed with one or more additives, including at least a color additive to impart a color to the consolidated thermoplastic composite laminate during the over-molding process. The over-mold polymer material has a melting temperature that is greater than, or equal to, a melting temperature of the laminate polymer material, and that is less than a thermal degradation temperature of the laminate polymer material.

Abstract: A method for continuously fabricating a composite sandwich structure includes the steps of: (1) preheating a laminate to a preforming temperature above a glass transition temperature of the laminate but below or equal to a crystalline melt temperature of the laminate as the laminate is substantially continuously moved through a preheating zone, wherein the laminate comprises a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) consolidating the laminate as the laminate is substantially continuously moved through a consolidation zone in line with the preheating zone to form a continuous length of the composite sandwich structure; (3) moving the composite sandwich structure, substantially continuously, through at least one of a texturing zone and a coating zone; and (4) incrementally applying at least one of a surface texture and a surface coating to at least one surface of the composite sandwich structure.

Abstract: A method for continuously fabricating a composite sandwich structure includes the steps of: (1) moving a laminate, substantially continuously, through a preheating zone, wherein the laminate includes a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) preheating the laminate to a preforming temperature above a glass transition temperature of the laminate and below or equal to a crystalline melt temperature of the laminate as the laminate is being moved through the preheating zone; (3) moving the laminate, substantially continuously, through a consolidation zone; and (4) consolidating the laminate as the laminate is being moved through the consolidation zone to form a continuous length of the composite sandwich structure.

Abstract: A method for continuously fabricating a composite sandwich structure includes the steps of: (1) preheating a laminate to a preforming temperature above a glass transition temperature of the laminate but below or equal to a crystalline melt temperature of the laminate as the laminate is substantially continuously moved through a preheating zone, wherein the laminate comprises a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) consolidating the laminate as the laminate is substantially continuously moved through a consolidation zone in line with the preheating zone to form a continuous length of the composite sandwich structure; (3) moving the composite sandwich structure, substantially continuously, through at least one of a texturing zone and a coating zone; and (4) incrementally applying at least one of a surface texture and a surface coating to at least one surface of the composite sandwich structure.

Abstract: A method for continuously fabricating a composite sandwich structure includes the steps of: (1) moving a laminate, substantially continuously, through a preheating zone, wherein the laminate includes a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) preheating the laminate to a preforming temperature above a glass transition temperature of the laminate and below or equal to a crystalline melt temperature of the laminate as the laminate is being moved through the preheating zone; (3) moving the laminate, substantially continuously, through a consolidation zone; and (4) consolidating the laminate as the laminate is being moved through the consolidation zone to form a continuous length of the composite sandwich structure.