A method of making a panel assembly that includes forming a thermoplastic panel, placing a thermoset portion into a pocket in a mold, placing an attachment member into the pocket in the mold, positioning the thermoplastic panel in the mold, cooling the thermoplastic panel while heating the thermoset portion to flow at least a portion of the thermoset portion into openings defined in the thermoplastic panel, and cooling the panel assembly so that the thermoset portion hardens, thereby securing the attachment member to the thermoplastic panel.

Disclosed is a non-flammable thermal insulating composite substrate for motor vehicles including: a textile component constituted by a layer of needle-sewn non-woven fabric composed of a percentage of pre-oxidized polyacrylonitrile fiber included between 40% and 70%, preferably 58% and of the remaining percentage of polyethylene glycol-terephthalate fiber, the textile component having weight preferably 400 gr/m.sup.2; and a barrier fixed to the textile component using a spreading process, constituted by a thermoplastic resin based on low density polyethylene added with non-halogen flame retardants, the barrier having weight preferably 100 gr/m.sup.2. The composite substrate has the following features: a thickness included between 2 mm and 5 mm, preferably 3.8 mm; a weight included between 300 gr/m.sup.2 and 700 gr/m.sup.2, preferably 500 gr/m.sup.2; odorless; no emission of fumes; dimensionally stable, even at heatstroke, with a maximum variation of 1%; and non-flammability.

A shape forming tool for pre-carbonization compression of a fibrous preform includes a female forming tool comprising a die recess, a first die half configured to be received by the die recess, a second die half configured to be received by the die recess, an expander tool coupled between the first die half and the second die half. The expander tool is configured to move the first die half laterally toward a first side of the female forming tool away from the second die half to compress the fibrous preform between the first die half and the female forming tool. The expander tool is further configured to move the second die half laterally toward a second side of the female forming tool away from the first die half to compress the fibrous preform between the second die half and the female forming tool.

A method for shape forming a composite part includes positioning an oxidized PAN fiber preform between a first forming mold and a second forming mold. The first forming mold is pivotally coupled to the second forming mold such that rotating the first forming mold toward the second forming mold compresses the preform therebetween. The method can further include forming the preform into a shaped body first as the first forming mold is rotated toward the second forming mold. As the first forming mold rotates toward the second forming mold, a compressing force can first clamp a first side of the preform in place, and then the compressing force progresses along the preform from a first side of the preform, located at the hinge side of the first forming mold, toward a second side of the preform, located at a free side of the first forming mold.

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.

A repair method is provided during which a thermoplastic patch is arranged on a thermoplastic aerospace component. An ultrasonic horn is arranged on the thermoplastic patch. The thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn. The thermoplastic patch contacts the ultrasonic horn. The thermoplastic patch is continuous ultrasonic welded to the thermoplastic aerospace component using the ultrasonic horn.

A shape forming tool for pre-carbonization shaping of a fibrous preform is provided, comprising a rounded preform and an inner die to fit within the preform. The rounded preform may be a cylindrical, conical, or frustoconical shape. The inner die may be of a non-uniform diameter and/or have complex features. The preform may shrink to conform to the inner die.