A method of fabricating a thermoplastic component using inductive heating is described. The method includes positioning a plurality of induction heating coils to define a process area for the thermoplastic component, wherein the plurality of induction heating coils comprises a first set of coils and a second set of coils. The method also includes controlling a supply of electricity provided to the plurality of inductive heating coils to intermittently activate the coils. The intermittent activation is configured to facilitate prevention of electromagnetic interference between adjacent coils.

A method and apparatus for forming a bonded joint on a composite structure is presented. An apparatus carrying a first workpiece is positioned relative to a second workpiece. A vacuum is applied to the first workpiece and a portion of the second workpiece. A bladder on a first surface of a housing of the apparatus is deflated. Deflating the bladder positions the first workpiece such that adhesive having a desired thickness is positioned between the first workpiece and the second workpiece. The adhesive positioned between the first workpiece and the second workpiece is cured.

A method and apparatus for forming a bonded joint on a composite structure is presented. An apparatus carrying a first workpiece is positioned relative to a second workpiece. A vacuum is applied to the first workpiece and a portion of the second workpiece. A bladder on a first surface of a housing of the apparatus is deflated. Deflating the bladder positions the first workpiece such that adhesive having a desired thickness is positioned between the first workpiece and the second workpiece. The adhesive positioned between the first workpiece and the second workpiece is cured.

A joint structure (1) for a composite member made from a composite material. The joint structure includes a plate for increasing thickness (40a, 40b) adhered to at least one side of the composite member (10). The composite member (10) and a counterpart member (20) are fastened together by inserting and fixing a fastener member (30) into a through-hole (24, 26) formed through the composite member (10), the plate for increasing thickness (40a, 40b), and the counterpart member (20) to be joined to the composite member.

A joint structure (1) for a composite member made from a composite material. The joint structure includes a plate for increasing thickness (40a, 40b) adhered to at least one side of the composite member (10). The composite member (10) and a counterpart member (20) are fastened together by inserting and fixing a fastener member (30) into a through-hole (24, 26) formed through the composite member (10), the plate for increasing thickness (40a, 40b), and the counterpart member (20) to be joined to the composite member.

A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.

A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.

An off-axis prepreg material manufacturing machine may include a robot configured to position a prepreg piece adjacent to an end of a prepreg layer. The machine may additionally include an alignment system configured to sense a position of the prepreg piece relative to the prepreg layer and generate a position signal representative thereof. The machine may also include a controller configured to receive the position signal and cause the robot to adjust the position of the prepreg piece such that an end edge of the prepreg piece and an end edge of the prepreg layer are in substantially abutting contact.

An off-axis prepreg material manufacturing machine may include a robot configured to position a prepreg piece adjacent to an end of a prepreg layer. The machine may additionally include an alignment system configured to sense a position of the prepreg piece relative to the prepreg layer and generate a position signal representative thereof. The machine may also include a controller configured to receive the position signal and cause the robot to adjust the position of the prepreg piece such that an end edge of the prepreg piece and an end edge of the prepreg layer are in substantially abutting contact.

Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.