Abstract: A composite structure includes a thermoplastic material and axial fibers and radial fibers arranged within the thermoplastic material. The thermoplastic material can define a substructure of the composite structure. The fibers can be continuous and/or discontinuous fibers. The substructure can be a first substructure and the composite structure can further include a second substructure. Opposing ends of the first substructure and the second substructure are bonded with one another to form a tubular structure. The composite structure can exhibit enhanced damping characteristics such as having a damping coefficient greater than 0.5 lbf s/in. In some cases, this can limit vibrations of the tubular structure to less than 5.0 m/s2.

Abstract: Disclosed herein are systems and techniques for producing complex components using a reinforced thermoplastic material. The complex components can include contoured or curved outer surfaces, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as that adapted to define a rim of the bicycle. Thermal bonding can be used to join multiple reinforced thermoplastic materials to one another in order to form a cavity of the wheel component or other complex shape. In certain examples, a portion of a tooling assembly can be pressurized to maintain a shape of the cavity during thermal bonding and cooling. This can remove the need for a sacrificial bladder or other structure that would maintain the shape of the cavity, allowing for a seamless final component, optionally absent indicia of bladder exit or other seams.

Abstract: Disclosed herein are systems and techniques for producing complex components using a reinforced thermoplastic material. The complex components can include contoured or curved outer surfaces, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as that adapted to define a rim of the bicycle. Thermal bonding can be used to join multiple reinforced thermoplastic materials to one another in order to form a cavity of the wheel component or other complex shape. In certain examples, a portion of a tooling assembly can be pressurized to maintain a shape of the cavity during thermal bonding and cooling. This can remove the need for a sacrificial bladder or other structure that would maintain the shape of the cavity, allowing for a seamless final component, optionally absent indicia of bladder exit or other seams.

Abstract: Disclosed herein are systems and techniques for producing complex components using a reinforced thermoplastic material. The complex components can include contoured or curved outer surfaces, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as that adapted to define a rim of the bicycle. Thermal bonding can be used to join multiple reinforced thermoplastic materials to one another in order to form a cavity of the wheel component or other complex shape. In certain examples, a portion of a tooling assembly can be pressurized to maintain a shape of the cavity during thermal bonding and cooling. This can remove the need for a sacrificial bladder or other structure that would maintain the shape of the cavity, allowing for a seamless final component, optionally absent indicia of bladder exit or other seams.