Methods of joining rotor blade components using thermoplastic welding

A method for welding thermoplastic rotor blade components together the method comprising:

• arranging a first thermoplastic rotor blade component and a second thermoplastic rotor blade component together at an interface;
• determining a size of a tolerance gap between the first and second thermoplastic rotor blade components at the interface;
• placing a thermoplastic insert between the first and second thermoplastic rotor blade components at the interface, the thermoplastic insert being larger than the tolerance gap;
• heating the thermoplastic insert and the first and second thermoplastic rotor blade components such that the thermoplastic insert begins to flow so as to fill the tolerance gap between the first and second thermoplastic rotor blade components;
• applying pressure to the interface such that the thermoplastic insert and the first and second thermoplastic rotor blade components remain substantially in direct contact with each other at the interface;
• and,
• subsequently welding the thermoplastic insert and the first and second thermoplastic rotor blade components together at the interface, wherein the heat and the applied pressure between the thermoplastic insert and the first and second thermoplastic rotor blade components at the interface maintain the thermoplastic insert and the first and second rotor blade components substantially in direct contact at the interface during welding.