A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.

A fiber structure includes a plurality of weft layers and of warp layers interlinked by multilayer three-dimensional weaving, the fiber structure having at least first and second portions that are adjacent in the warp direction, the first portion presenting, in a direction perpendicular to the warp and weft directions, a thickness that is greater than the thickness of the second portion, wherein the first portion has at its core at least one fiber fabric obtained by three-dimensional weaving of warp yarns and weft yarns in the form of a Mock Leno weave grid, the at least one fabric being present between two skins present at the surface of the first portion and being linked to the skins by warp yarns belonging to the skins that are locally deflected into the fabric.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.

A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.