Abstract: There is provided a duct and an associated preform and method. The duct is formed of a thermoplastic material and is lightweight, strong, flame and smoke resistant, and non-toxic. The duct is formed from a flat laminate and does not require a specialized, disposable mandrel for supporting conventional thermoset plies. Preferably, the duct is formed from a preform, which is cut according to the desired shape and size of the duct so that trimming after the duct has been formed is not required. Additionally, features such as holes and spud locations can be provided by cutting or marking the preform before forming the duct. Each duct can be formed of multiple articulated segments that are joined by connectors.

Abstract: There are provided apparatuses and related methods for preforming sheets to form preforms for forming ducts. The preforms can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape of the duct. For example, rollers, rods, tubes, or a funnel can be used to bend the sheet.

Abstract: There is provided an apparatus and method for consolidation joining a thermoplastic preform to form a duct. The apparatus includes first and second longitudinally extending support structures. The first support structure at least partially defines a cavity for supporting the preform in a desired configuration of the duct. The second support structure extends in the cavity such that the preform can be supported between the first and second support structures. The second support structures can include an elastomeric device that is configured to adjust radially and urge the interface of the preform against the first support structure. A heater is configured to heat an interface of the preform to above a glass transition temperature. The resulting duct is has a longitudinal consolidation joint and defines a passage.