A method of removing a vacuum bag from a composite mold. Removable strips are placed around the perimeter of the component parts and across the parts to create natural break points in the consumable materials used during manufacture of a composite product, e.g. wind turbine blade. The vacuum bag, and other consumable layers, are placed over the removable strip such that when the strips are pulled, the strip tears, in a controlled and complete manner, through each layer of consumables. This eliminates the need to use a knife/scissor to remove the finished product, thereby avoiding risk of injury.

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

A method of induction welding a first carbon fiber thermoplastic composite (TPC) to a second carbon fiber thermoplastic composite (TPC) using an induction coil includes aligning the first TPC with the second TPC to form a weld interface area, flexing a heat sink onto a surface of the first TPC between the weld interface area and the induction coil, and inductively heating the weld interface area with the induction coil.

A machine (1) and a method for thermobonding using an emission of electromagnetic waves (13), for example microwaves, to activate one or a plurality of adhesive layers located between a support and one or a plurality of layers of flexible covering, through a bed of particles (4) fluidized by a humidified gas. A multi-layer upholstery item including at least one non-permeable layer and produced in a single operation is also described.

A composite sandwich panel includes a first composite part and a second composite part. A plurality of stiffeners extend between the first and second composite parts. A fiberglass composite perimeter edge closeout is positioned along one or more edges of the first and second composite parts. The fiberglass composite perimeter edge closeout controls a magnetic flux to bond the first and second composite parts to the plurality of stiffeners.

A method for connecting two components is proposed where a pressure acting on an adhesive between two join partners is supported by an auxiliary body which rests on a cutout of one of the components. Both components to be connected together and the auxiliary body are covered by a vacuum film and once the air has been sucked out, the compressive force is generated below the vacuum film.

A joining method is provided during which a first thermoplastic component joint section and a second thermoplastic component joint section are arranged between first tooling and second tooling. The second thermoplastic component joint section is abutted against the first thermoplastic component joint section at a joint area. The first thermoplastic component joint section is joined to the second thermoplastic component joint section to provide a unitized thermoplastic structure. The joining includes: pressing the first thermoplastic component joint section against the second thermoplastic component joint section at the joint area between the first tooling and the second tooling using a pressure device; and heating the first thermoplastic component joint section and the second thermoplastic component joint section at the joint area using a first heater configured with the first tooling. The unitized thermoplastic structure is cooled at the joint area using a first cooler configured with the first tooling.

An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

Described herein are methods and systems for manufacturing composite stringers using independently movable pallets with independent vacuum controls. Specifically, a stringer forming system comprises a base plate and a plurality of sets of pallets (e.g., two or more sets of pallets), slidably coupled to the base plate and forming an adjustable cavity. Each pallet comprises a primary vacuum zone, fluidly connected to a separate vacuum port. The system allows for independent application of a reduced pressure to the primary vacuum zone of each pallet. For example, a reduced pressure is applied only to pallets that are already covered with a composite layup and to pallets that are being covered. Any pallets that are exposed are kept at an ambient pressure and decoupled from a vacuum source, thereby reducing the vacuum leakage through the overall system. As the composite layup is being formed over new pallets, these new pallets are subjected to the reduced pressure.

A heat sink for use in induction welding includes a number of tiles, wherein the tiles are electrically non-conductive and have a thermal diffusivity of greater than about 25 mm2/sec. A joint flexibly joins the tiles together.