Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of multiple pairs of shapeable and flexible bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.

Abstract: A nacelle for a wind turbine system includes a plurality of interconnected curved nacelle thermoplastic composite material panels, each curved nacelle thermoplastic composite material panel having a plurality of interconnecting edges, a foam core, an inner skin, an outer skin, and a plurality of three-dimensional fiber bundles tying the inner skin and the outer skin to each other through the foam core, inhibiting delamination, wherein the plurality of three-dimensional Z-axis fiber bundles include Z-axis fibers, which extend through the foam core from the inner skin to the outer skin, include opposite ends that are thermocured into and with the inner skin and outer skin.

Abstract: A method of processing a thermoplastic composite tubular lineal comprising providing a pre-pregged thermoplastic composite around an elongated stationary mandrel; wrapping the pre-pregged thermoplastic composite with a release material; heating the stationary mandrel so that the pre-pregged thermoplastic composite melts and the release material contracts, exerting pressure on the pre-pregged material; cooling the pre-pregged material and release material so as to form a thermoplastic composite tubular lineal in its final configuration; pulling the thermoplastic composite tubular lineal downstream; and removing the release material from the thermoplastic composite tubular lineal.

Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of one or more pairs of shapeable and flexible dual-temperature bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of multiple pairs of shapeable and flexible bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.

Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.

Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours. The 3D thermoplastic pultrusion system and method including at least one of one or more pairs of shapeable and flexible dual-temperature bands and a rotating assembly that rotates the one or more sets of 3D thermoplastic forming machines to impart a twist to the thermoplastic composite.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A radome for housing a radar system comprises a plurality of interconnected curved radome thermoplastic composite material panels, each curved radome thermoplastic composite material panel having a plurality of interconnecting edges, a foam core, an inner skin, an outer skin, and a plurality of three-dimensional fiber bundles tying the inner skin and the outer skin to each other through the foam core, inhibiting delamination. The radome includes a hydrophobic exterior surface that is self-cleaning and requires zero maintenance for 25 years.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A 3D Z-axis fiber composite pallet, comprising a Z-axis reinforced sandwich panel including a bottom surface with a plurality of bolted-on and/or structurally bonded blocks that accommodate forks of a forklift there between, and a tough coating applied to surfaces of the 3D Z-axis fiber composite pallet.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.

Abstract: A 3D thermoplastic pultrusion system, comprises one or more sets of 3D thermoplastic forming machines; a CNC control system controlling the one or more sets of 3D thermoplastic forming machines to form a heated prepreg thermoplastic composite material into a 3D thermoplastic composite pultrusion, the one or more sets of 3D thermoplastic forming machines include a plurality of motion control CNC rotational motors and CNC actuators operatively coupled to the motion control CNC rotational motors, a flexible chilled band shapeable by the CNC actuators to form the heated prepreg thermoplastic composite material into the thermoplastic composite pultrusion, and bearings that the motion control CNC rotational motors pivot the actuators about and hold the actuators in position during a consolidation process.

Abstract: A 3D thermoplastic pultrusion system and method based upon a 3D variable die system and including one or more sets of 3D thermoplastic forming machines to continuously produce thermoplastic composite pultrusions with at least one of varying cross-section geometry and constant surface contours, varying cross-section geometry and varying surface contours, and constant cross-section geometry and varying surface contours.