Method for forming a heated thermoplastic composite into a closed profile using a tooling

A method for forming a heated thermoplastic composite material into a closed profile using a tooling, the method comprising:

• a) forming, during a first forming stage, a heated thermoplastic composite material in a first space between a male tooling part and a female tooling part, the thermoplastic composite material comprising, after having performed the first forming stage, a first segment, a second segment, and an intermediate segment integrally connecting the first segment to the second segment, wherein the intermediate segment is arranged in the first space, and wherein the first segment and the second segment extend outside of said first space;
• b) forming, during at least one second forming stage, the thermoplastic composite material by engaging the first segment and/or second segment with at least one auxiliary tooling part to thereby bring the first and second segments closer together;
• and
• c) forming, during a third forming stage, the thermoplastic composite material by pressing, using a pressing tooling part, the thermoplastic composite material around the male tooling part thereby creating a seam between the first and second segment, wherein during the third forming stage the intermediate segment and parts of the first segment and second segment associated with the seam are confined in a second space between the male tooling part, the female tooling part, and at least one among the pressing tooling part and the at least one auxiliary tooling part;
• wherein during the third forming stage, the second space is delimited by the male tooling part, the female tooling part, one or more auxiliary tooling parts among the at least one auxiliary tooling part, and the pressing tooling part, wherein the pressing tooling part is provided with one or more recesses, and wherein during the third forming stage, a part of the pressing tooling part presses onto the thermoplastic composite material directly and a part of the pressing tooling part presses onto the thermoplastic composite material through said one or more auxiliary tooling parts that are at least partially received in the one or more recesses of the pressing tooling part.