Continuous fiber reinforced thermoplastic composite usage in aerospace is increasing because of the inherent toughness and processing possibilities of these materials. The design of high performance thermoplastic sandwich panels has proven difficult to date because of the high processing temperatures required for these materials. Based on butt joining of thermoplastic composites, a sandwich panel concept has been developed. It is a multi-cell structure, where two skins are connected by parallel webs. The sandwich panel is co-consolidated in a single autoclave step. The connection between skins and webs is achieved by an injection molded filler.
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