Ultrasonic welding thermoplastic material using energy transmission material

A method, comprising:

• arranging a first thermoplastic composite body on a rigid support structure, the first thermoplastic composite body contacting the rigid support structure;
• arranging a second thermoplastic composite body on the first thermoplastic composite body, the second thermoplastic composite body contacting the first thermoplastic composite body;
• arranging energy transmission material on the second thermoplastic composite body, wherein the first thermoplastic composite body and the second thermoplastic composite body are disposed between the rigid support structure and the energy transmission material;
• ultrasonic welding the second thermoplastic composite body to the first thermoplastic composite body using an ultrasonic horn, wherein the energy transmission material is arranged between the second thermoplastic composite body and the ultrasonic horn;
• and
• providing an aircraft component, wherein the aircraft component includes the first thermoplastic composite body and the second thermoplastic composite body welded to the first thermoplastic composite body.