Fabrication method and apparatus for creating large and/or complex thermoplastic composite components

A consolidation tool comprising:

• a base, the base having a tool surface on a top of the base;
• a cavity recessed downwardly into the tool surface of the base;
• a first insert removably positioned in the cavity, the first insert having a first cross-section configuration;
• a groove in the first insert, the groove having a configuration for receiving a tube of thermoplastic material in the groove and holding the tube of thermoplastic material in the groove as the tube of thermoplastic material is slit and spread out as a sheet of thermoplastic material across the groove;
• a pressure bladder, the pressure bladder being configured for being positioned in the groove on top of the sheet of thermoplastic material spread across the groove, the pressure bladder being inflatable in the groove to exert a pressure force against the sheet of thermoplastic material spread across the groove and press the sheet of thermoplastic material into the groove;
• and,
• a press supported on the base, the press having a bottom surface on a bottom of the press, the press being moveable toward and away from the tool surface of the base, the bottom surface of the press being configured to engage against the tool surface of the base and the pressure bladder positioned in the groove on top of the sheet of thermoplastic material spread across the groove in response to the press being moved toward the tool surface of the base with the sheet of thermoplastic material spread across the groove being pressed into the groove by the pressure bladder inflated in the groove and the bottom surface of the press engaging against the tool surface of the base and the pressure bladder.

A method of consolidating thermoplastic composite material comprising:

• forming a tube of thermoplastic material by braiding thermoplastic tape into the tube of thermoplastic material;
• positioning the tube of thermoplastic material in a groove of an insert on a tool surface;
• slitting the tube of thermoplastic material in the groove and spreading out the tube of thermoplastic material as a sheet of thermoplastic material across the groove;
• positioning a pressure bladder on the sheet of thermoplastic material spread out across the groove;
• moving a press into engagement with the tool surface and the pressure bladder positioned in the groove on top of the sheet of thermoplastic material spread across the groove with the sheet of thermoplastic material spread across the groove being pressed into the groove by the pressure bladder and by the press engaging against the tool surface.