Abstract: A method is provided for forming a thermoplastic structure. During this method, a substrate is provided. The substrate includes a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic. The substrate fibers are arranged in a substrate pattern. A first layer is deposited on the substrate using an automated fiber placement device. The first layer includes a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic. The first layer fibers are arranged in a first layer pattern that is different than the substrate pattern. A blank is stamped into the thermoplastic structure. The blank includes the substrate and the first layer where the first layer thermoplastic is consolidated with the substrate thermoplastic.

Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.

Abstract: A multilayer heating structure for controlling ice accumulation on a surface of an aircraft includes a carbon nano-tube (CNT) heater. The heater includes: a CNT layer; a first encapsulation layer disposed on a first side of the CNT layer formed of a first encapsulation layer thermoplastic material; and a second encapsulation layer disposed on a second side of the CNT layer formed of a second encapsulation layer thermoplastic material. The structure further includes for and aft composite structures. The first and second encapsulation layer thermoplastic materials have higher melting temperatures that one or both the fore composite structure thermoplastic material and the aft composite structure thermoplastic material.

Abstract: A modular tooling arrangement includes a base member comprising a planar working surface, a frame circumscribing a first cavity at least partially defined by the planar working surface, and a plurality of plates configured to be received in the first cavity for forming a second cavity of a desired shape and size. The plurality of plates at least partially define the second cavity configured to receive a work piece. The plurality of plates may be replaced with plates of various sizes to vary at least one of the size and shape of the second cavity.