Abstract: A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector comprises: manufacturing a tubular hub portion which extends substantially parallel to a central axis C, the hub portion comprising a thermoplastic polymer reinforced with continuous, circumferentially-oriented fibre reinforcement; placing the hub portion into a mould featuring at least one cavity; and introducing polymer into the mould so as to fill the at least one cavity to form a flange portion around the hub portion.

Abstract: During a formation method, a first component and a second component are provided. The first component is configured from or otherwise includes a first fiber-reinforced thermoplastic composite. The first component also includes a base and a material buildup on a portion of the base. The second component is configured from or otherwise includes a second fiber-reinforced thermoplastic composite. The second component is arranged with the first component. The second component abuts the material buildup. The second component is vibration welded to the first component to provide a weld joint between the first component and the second component. At least a portion of the material buildup is displaced during the vibration welding.

Abstract: A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Abstract: A method is provided for manufacturing a container. During this method, a baffle is provided. The baffle is configured from or otherwise includes baffle thermoplastic material. A sidewall is formed using an additive manufacturing device. The sidewall is bonded to the baffle during the forming of the sidewall. The sidewall circumscribes the baffle. The sidewall is configured from or otherwise includes sidewall thermoplastic material. The container includes an internal chamber, the baffle and the sidewall. The sidewall forms an outer peripheral boundary of the internal chamber. The baffle is arranged within the internal chamber.

Abstract: A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Abstract: A method is provided for manufacturing a container. During this method, a baffle is provided. The baffle is configured from or otherwise includes baffle thermoplastic material. A sidewall is formed using an additive manufacturing device. The sidewall is bonded to the baffle during the forming of the sidewall. The sidewall circumscribes the baffle. The sidewall is configured from or otherwise includes sidewall thermoplastic material. The container includes an internal chamber, the baffle and the sidewall. The sidewall forms an outer peripheral boundary of the internal chamber. The baffle is arranged within the internal chamber.

Abstract: A method is provided for manufacturing a container. During this method, a baffle is provided. The baffle is configured from or otherwise includes baffle thermoplastic material. A sidewall is formed using an additive manufacturing device. The sidewall is bonded to the baffle during the forming of the sidewall. The sidewall circumscribes the baffle. The sidewall is configured from or otherwise includes sidewall thermoplastic material. The container includes an internal chamber, the baffle and the sidewall. The sidewall forms an outer peripheral boundary of the internal chamber. The baffle is arranged within the internal chamber.

Abstract: A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Abstract: An apparatus is provided for rotational equipment. This apparatus includes a rotor blade including an airfoil body, a spar structure and a cuff. The airfoil body extends spanwise from a base to a tip. The airfoil body extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil body extends laterally between a first side and a second side. The spar structure extends spanwise within and supports the airfoil body. The cuff projects out from the spar structure and away from the base of the airfoil body. The cuff is formed integral with the spar structure. The cuff and the spar structure are configured from or otherwise include thermoplastic material.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A tacking device may comprise: a handle; a main body extending from a first end of the handle to a second end of the handle; and a plurality of soldering irons, each soldering iron in the plurality of soldering irons extending from a first side of the main body through the main body to a second side of the main body, each soldering iron in the plurality of soldering irons including a piercing end disposed on the second side of the main body.

Abstract: During a formation method, a first component and a second component are provided. The first component is configured from or otherwise includes a first fiber-reinforced thermoplastic composite. The first component also includes a base and a material buildup on a portion of the base. The second component is configured from or otherwise includes a second fiber-reinforced thermoplastic composite. The second component is arranged with the first component. The second component abuts the material buildup. The second component is vibration welded to the first component to provide a weld joint between the first component and the second component. At least a portion of the material buildup is displaced during the vibration welding.

Abstract: A method of repairing a defect of a thermoplastic component is provided. The thermoplastic component has a thermoplastic material at the defect having a first melting temperature, and the defect has a contact surface (TC contact surface). The method includes a) providing a patch comprising a second thermoplastic material having a second melting temperature that is below the first melting temperature. The patch includes a contact surface (TP contact surface); b) disposing a portion of a heating element between the TC contact surface and the TP contact surface. The heating element is operable to heat up as a result of electrical resistance; c) forcing the TP surface toward the TC surface; and d) inputting energy into the heating element to cause the heating element to heat and maintain the TP surface at or above the second melting temperature to produce bonding between the thermoplastic component and the patch.

Abstract: A tacking device may comprise: a handle; a main body extending from a first end of the handle to a second end of the handle; and a plurality of soldering irons, each soldering iron in the plurality of soldering irons extending from a first side of the main body through the main body to a second side of the main body, each soldering iron in the plurality of soldering irons including a piercing end disposed on the second side of the main body.

Abstract: A method of and system for removing a portion of a thermoplastic component is provided. The component includes a thermoplastic material having a melting temperature. The method includes: a) providing a glider that includes an electrically conductive material operable to produce thermal energy resulting from electrical resistance; b) heating a portion of the glider with electrical energy to a glider operating temperature that is equal or greater than the melting temperature; and c) removing the portion by engaging the component with the glider and translating one of the glider or the component relative to the other. The engagement of the glider and the component causes an amount of the thermoplastic material to melt, and the translation of the one of the glider or the component relative to the other removes the portion from the thermoplastic component.

Abstract: An apparatus for forming a composite shaft may comprise an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly. The axial fiber strip dispensing assembly may include a plurality of fiber strip guides located circumferentially about a center axis. The plurality of fiber strip guides may be configured to dispense a plurality of circumferentially adjacent first fiber strips with the plurality of circumferentially adjacent first fiber strips extending in a generally axial direction. The hoop fiber strip dispensing assembly may be configured to dispense a second fiber strip circumferentially about the center axis.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: An airfoil assembly includes an airfoil body extending from a root to a tip defining a longitudinal axis therebetween. The airfoil body includes a leading edge between the root and the tip. A sheath is direct deposited on the airfoil body. The sheath includes at least one metallic material layer conforming to a surface of the airfoil body. In accordance with another aspect, a method for assembling an airfoil assembly includes directly depositing a plurality of material layers on an airfoil body to form a sheath. In accordance with some embodiments, the method includes partially curing the airfoil body.

Abstract: An apparatus for forming a composite shaft may comprise an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly. The axial fiber strip dispensing assembly may include a plurality of fiber strip guides located circumferentially about a center axis. The plurality of fiber strip guides may be configured to dispense a plurality of circumferentially adjacent first fiber strips with the plurality of circumferentially adjacent first fiber strips extending in a generally axial direction. The hoop fiber strip dispensing assembly may be configured to dispense a second fiber strip circumferentially about the center axis.