Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism is provided. The method includes fixing a molded-in insert in a mold cavity. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, and has a substantially concave configuration, and the groove has a groove radius of 0.025 inch or greater, and greater than or equal to a groove depth. The method includes introducing a fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert, enclosing the mold cavity, heating and compressing the material in the mold cavity to consolidate the material around the molded-in insert and to form a consolidated fiber reinforced thermoplastic composite structure with the molded-in insert, cooling the structure, and removing the structure with the molded-in insert from the mold cavity.

Abstract: A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism is provided. The method includes fixing a molded-in insert in a mold cavity. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, and has a substantially concave configuration, and the groove has a groove radius of 0.025 inch or greater, and greater than or equal to a groove depth. The method includes introducing a fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert, enclosing the mold cavity, heating and compressing the material in the mold cavity to consolidate the material around the molded-in insert and to form a consolidated fiber reinforced thermoplastic composite structure with the molded-in insert, cooling the structure, and removing the structure with the molded-in insert from the mold cavity.

Abstract: In an embodiment of the disclosure, there is provided a molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

Abstract: Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes are created from a unidirectional composite fiber tape and poured into a reservoir of a mold, creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.

Abstract: In an embodiment of the disclosure, there is provided a molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.