Thrust reverser cascade array and method for producing the same

A cascade array, comprising:

• a plurality of comb subassemblies, each said comb subassembly comprising:
• a strongback comprising a first thermoplastic material forming a first side surface of the strongback;
• and
• a plurality of vanes formed by a second thermoplastic material overmolding the first thermoplastic material of the strongback, the plurality of vanes extending outwardly from the first side surface of the strongback, each vane of the plurality of vanes comprising a first lateral end and an opposite second lateral end, the first lateral end contiguous with the strongback, the second thermoplastic material overmolding the first thermoplastic material forming at least one fillet of each vane of the plurality of vanes, the at least one fillet including a first fillet disposed at the first lateral end of each vane of the plurality of vanes and a second fillet disposed at the second lateral end of each vane of the plurality of vanes, the first fillet extending between each vane of the plurality of vanes and the strongback, the second thermoplastic material forming each vane of the plurality of vanes spaced from adjacent portions of the second thermoplastic material along a length of the first side surface;
• wherein each second fillet of a first comb subassembly of the plurality of comb subassemblies is welded to a second comb subassembly of the plurality of comb subassemblies;
• wherein the first thermoplastic material is different than the second thermoplastic material.