Forming thermoplastic structure stamping blank using automated fiber placement device

A method for forming a thermoplastic structure, comprising:

• providing a substrate, the substrate including a substrate thermoplastic and a plurality of substrate fibers disposed within the substrate thermoplastic, the plurality of substrate fibers arranged in a substrate pattern, and a first of the plurality of substrate fibers following a straight trajectory within the substrate thermoplastic;
• depositing a first layer on a surface of the substrate using an automated fiber placement device, the first layer including a first layer thermoplastic and a plurality of first layer fibers disposed within the first layer thermoplastic, the plurality of first layer fibers arranged in a first layer pattern that is different than the substrate pattern, and a first of the plurality of first layer fibers following a non-straight trajectory within the first layer thermoplastic when viewed in a reference plane parallel to the surface of the substrate;
• providing a second substrate, the second substrate including a second substrate thermoplastic and a plurality of second substrate fibers disposed within the second substrate thermoplastic, and the plurality of second substrate fibers arranged in a second substrate pattern;
• depositing a second layer on the second substrate using the automated fiber placement device, the second layer including a second layer thermoplastic and a plurality of second layer fibers disposed within the second layer thermoplastic, and the plurality of second layer fibers arranged in a second layer pattern that is different than the second substrate pattern;
• stacking the second substrate with the second layer onto the substrate with the first layer to provide a multi-layer stack;
• consolidating the multi-layer stack together to provide a blank;
• and
• stamping the blank to provide the thermoplastic structure.