CPC B29C 70/42 (2013.01) [B29C 43/003 (2013.01); B29C 43/18 (2013.01); B29C 66/721 (2013.01); B29K 2101/12 (2013.01); B29K 2105/06 (2013.01); B29L 2031/3076 (2013.01)] | 19 Claims |
1. A method for forming a fiber-reinforced thermoplastic control surface, comprising:
stacking plies of thermoplastic composite sheets to a desired thickness to form a first skin;
transferring the first skin to an overmolding tool;
heating the overmolding tool;
compressing, via the overmolding tool, the first skin;
injecting a discontinuous fiber-reinforced thermoplastic material between the overmolding tool and the first skin to form a stiffener structure;
simultaneously consolidating the first skin and the stiffener structure, wherein the first skin is formed into a desired shape in response to being compressed by the overmolding tool;
attaching the first skin to a second skin; and
attaching a sidewall between and to the first skin and the second skin, wherein the sidewall at least partially encloses the stiffener structure between the first skin and the second skin.
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