Abstract: A cascade for a jet engine thrust reverser is fabricated by co-consolidating pre-consolidated thermoplastic strongbacks and vanes. The strongbacks are reinforced with continuous fibers, and the vanes are reinforced with discontinuous fibers.

Abstract: Continuous compression molded process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.

Abstract: A method and apparatus are used to pre-consolidate and de-bulk a thermoplastic composite ply stack prior to full consolidation and forming to the final part shape. Pre-consolidation and de-bulking is achieved by heating the ply stack to a temperature below the melting point of the thermoplastic in order to soften the plies, and then compress the ply stack.

Abstract: A method and apparatus are used to pre-consolidate and de-bulk a thermoplastic composite ply stack prior to full consolidation and forming to the final part shape. Pre-consolidation and de-bulking is achieved by heating the ply stack to a temperature below the melting point of the thermoplastic in order to soften the plies, and then compress the ply stack.

Abstract: A composite structure having a contoured cross section is fabricated by assembling a flat ply stack and forming the stack. The full plies in the stack are tacked through their entire thickness and the partial plies are tacked to individual ones of the full plies in a manner that enables the plies to slip in relation to each other, preventing wrinkling and distortion of the plies during forming.

Abstract: A method and apparatus for forming a stiffened thermoplastic panel is presented. The method may comprise placing a number of forming tools within a number of concave areas of a thermoplastic preform. The method may also place the thermoplastic preform with the number of forming tools within the number of concave areas on a thermoplastic lay-up to form a workpiece. The method may also position the workpiece within a tool. The tool may have a number of die liners configured to generate heat in response to a magnetic field. The method may also consolidate the workpiece to form the stiffened thermoplastic panel. Consolidating may comprise applying a magnetic field to the number of die liners to heat the workpiece to a consolidation temperature.

Abstract: A tool for compression molding a composite laminate charge has a tool face for compressing the charge. A flexible tool feature on the tool face forms a shape in the charge and compensates for tool surfaces that may be out-of-tolerance.

Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.

Abstract: Continuous compression molded process and apparatus for fabricating thermoplastic composite parts from pre-formed thermoplastic composite laminates with tooling dies have a staggered bevel feature at an entry side of the tooling dies. Staggering the length of the bevel feature in each section between bends in a surface contour along the width of the incoming edge of the tooling dies prevents excess material from being trapped and forming wrinkles in the finished thermoplastic part. The length of the taper in each section along the width of the tooling dies is aligned with a pulsed advancement distance of the pre-formed part.

Abstract: A composite structure having a contoured cross section is fabricated by assembling a flat ply stack and forming the stack. The full plies in the stack are tacked through their entire thickness and the partial plies are tacked to individual ones of the full plies in a manner that enables the plies to slip in relation to each other, preventing wrinkling and distortion of the plies during forming.