Injection molded composite blank and guide

A manufacturing process comprising the step of melt bonding at least one thermoplastic guide to a structural blank, wherein

• the at least one thermoplastic guide comprises a guide thermoplastic matrix, wherein the at least one thermoplastic guide includes a first thermoplastic guide having a guide shape comprising a guide shape width, a guide shape length and a guide shape height with a guide shape top side corresponding to a first side of a guide shape horizontal plane, a guide shape bottom side corresponding to a second side of the guide shape horizontal plane opposite the first side of the guide shape horizontal plane with the guide shape horizontal plane corresponding to the guide shape length and the guide shape width;
• the structural blank having a structural blank length, a structural blank width, and a structural blank height wherein the structural blank height is less than the structural blank width and the structural blank width is less than or equal to the structural blank length, and the structural blank comprises
• at least one ply containing a plurality of oriented continuous fibers in a structural blank thermoplastic or thermoset matrix wherein the plurality of oriented continuous fibers are selected from the group consisting of unidirectional oriented fibers and woven oriented fibers, and the at least one ply lies in a structural blank horizontal plane defined by the structural blank length and the structural blank width,
• a structural blank top side corresponding to one side of the structural blank horizontal plane,
• a structural blank bottom side opposite of the structural blank top side,
• a structural blank perimeter, and
• at least one structural blank hole passing from the structural blank top side to the
• structural blank bottom side;
• and
• the first thermoplastic guide is melt bonded to at least a portion of the structural blank top side, around the structural blank height, and to at least a portion of the structural blank bottom side wherein the guide thermoplastic matrix does not contact an internal edge of the at least one structural blank hole passing through a structural blank plane or a surface of the structural blank top side and the structural blank bottom side immediately adjacent a periphery of the at least one structural blank hole,
• the at least one thermoplastic guide further comprises a plurality of randomly dispersed fibers in the guide thermoplastic matrix, and
• wherein the at least one thermoplastic guide has at least one guide hole passing from a guide shape top side to a guide shape bottom side and the guide hole is not axially aligned with the at least one structural blank hole.