In-situ monitoring of thermoformable composites

A method for determining the quality of a structure, wherein constructing the structure includes the use of a thermoformable material comprising a thermoplastic, thermoset or metallic composite, and applying heat to the thermoformable material, the method comprising:

• a) capturing with an imaging device information pertaining to the structure and at least a portion of a component comprising the thermoformable material being applied to construct the structure,
• b) wherein capturing with the imaging device is carried out as the component of the thermoformable material is being applied to construct the structure, or after the thermoformable material has been applied, or both during the application and after the application of the thermoformable material to construct the structure;
• c) wherein said imaging device comprises a thermographic imaging component;
• d) processing the captured information from step a), including determining a differential heat flux of the applied component cooling after the application of heat, or determining a differential of heat flux of the applied component heating after the application of cooling;
• and
• e) determining, as the structure is being constructed, from said processing whether the differential of the heat flux of the applied component cooling or heating indicates a defect;
• f) tracking the thermographic imaging component and its location relative to the to the structure and at least a portion of the component comprising the thermoformable material being applied to construct the structure;
• g) wherein tracking in step f) is carried out as the imaging component is moved to image the structure or portion of the component comprising the thermoformable material being applied to construct the structure.