Abstract: An assembly of thermoplastic parts for forming a final composite part is presented where the assembly includes at least two prefabricated shells fabricated of thermoplastic. Each prefabricated shell has substantially the same shape as the final composite part and where the shapes of the prefabricated shells have dimensions that allow the prefabricated shells to be assembled into a nest for placement into a mold.

Abstract: An assembly of thermoplastic parts for forming a final composite part is presented where the assembly includes at least two prefabricated shells fabricated of thermoplastic. Each prefabricated shell has substantially the same shape as the final composite part and where the shapes of the prefabricated shells have dimensions that allow the prefabricated shells to be assembled into a nest for placement into a mold.

Abstract: An apparatus and method for making a mold or mold face includes a container having at least one opening. The apparatus also includes a flexible membrane that is retained to the container that extends across the opening of the container. The apparatus for making a mold further includes support media that is disposed within the container along with a vacuum valve that is connected to the container.

Abstract: An apparatus and method for making a mold or mold face includes a container having at least one opening. The apparatus also includes a flexible membrane that is retained to the container that extends across the opening of the container. The apparatus for making a mold further includes support media that is disposed within the container along with a vacuum valve that is connected to the container.

Abstract: Reaction injection molded (RIM) members and a method for forming such members are provided. The members can be formed in a mold cavity defining a contour that corresponds to the desired contour of the members. A foam material, such as a combination of polyol and isocyanate is injected into the cavity with a blowing agent so that the foam material expands to form the low density member. The average density of the member can be less than about 6 pounds per cubic foot.

Abstract: A mobile platform interior panel is provided that includes a body formed by a low pressure injection process and at least one of a duct and a layer of insulation integrated with the body. The low pressure injection process allows the duct and insulation to be integrated with the body simultaneously with the forming of the panel. More specifically, the duct is integrated with the panel by forming at least one internal cavity within the panel as the panel is formed. Additionally, the insulation is integrated with the panel by forming the panel using a low pressure injection material having desired insulative properties.