Methods of stamp-forming fiber-reinforced thermoplastic composite assemblies and related systems

A method of stamp-forming a fiber-reinforced thermoplastic composite assembly, the method comprising:

• applying a first low-melt film on at least one interface surface of at least one spar, wherein each spar of the at least one spar is formed of fiber-reinforced thermoplastic composite materials;
• loading the at least one spar onto at least one tooling segment such that the at least one interface surface is facing away from the at least one tooling segment;
• heating the at least one tooling segment to cause the first low-melt film to reach a first temperature, wherein the first temperature is above a crystallization temperature of the first low-melt film, and wherein the first temperature is below a melt temperature of a thermoplastic spar resin of the at least one spar;
• heating a skin blank to a second temperature, wherein the second temperature is above a melt temperature of a thermoplastic skin resin of the skin blank, and wherein the skin blank is a fiber-reinforced thermoplastic skin blank;
• draping the skin blank around the at least one tooling segment such that a first side of the skin blank faces an external surface of the at least one tooling segment;
• closing a stamp press around the skin blank and the at least one tooling segment, thereby pressing the skin blank into the at least one tooling segment and pressing the skin blank against the first low-melt film on the at least one interface surface, wherein closing the stamp press around the skin blank comprises causing the skin blank to conform to the at least one tooling segment;
• and
• co-consolidating the skin blank and the at least one spar within the stamp press, thereby forming the fiber-reinforced thermoplastic composite assembly.