Patent Publication Number: US-2021187998-A1

Title: Reinforced thermoplastic components and method of manufacture thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. Non-Provisional application Ser. No. 17/036,661 entitled “Reinforced Thermoplastic Components and Method of Manufacture Thereof,” filed Sep. 29, 2020, which claims the benefit of priority to U.S. Provisional Application No. 62/908,320 entitled “Reinforced Thermoplastic Components and Method of Manufacture Thereof,” filed Sep. 30, 2019, and to U.S. Provisional Application No. 62/982,611 entitled “Reinforced Thermoplastic Components and Method of Manufacture Thereof,” filed Feb. 27, 2020, the disclosures of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD 
     The described embodiments relate generally to high-strength, light-weight structures formed from reinforced thermoplastic materials, and more particularly, to structures formed from reinforced thermoplastic materials that can define a hollow cavity. 
     BACKGROUND 
     Composite materials can include a combination of two or more distinct materials that cooperate in a manner to complement and enhance their respective material properties. For example, composite materials can include a combination of relatively low weight materials and relatively high strength materials in order to produce components having a high strength to weight ratio. Such components can include intricate shapes and designs, including shapes tailored for specialty purposes. Specialty purpose components can, for example, include shapes having contoured surfaces, such as curved exteriors. Components can also have a hollow interior for weight reduction. In many traditional systems, thermoset materials are used to hold reinforcing materials in a matrix. Traditional approaches can produce overly brittle components, and limit component and manufacturing adaptability. Further, traditional manufacturing of components formed from composite materials, and resulting in a shape with a hollow interior, can involve complex, multi-step processes that increase cost and that can result in discontinuities or inconsistencies. As such, the need continues for techniques that can enhance the range of composite material component shapes and structures, without limiting functionality or performance of overall design. 
     SUMMARY 
     Examples of the present system and method are directed to reinforced thermoplastic components. More specifically, the examples described herein are directed to reinforced thermoplastic components having complex shapes, such as a shape having curved contours, substantially hollow interiors, and/or other properties. The reinforced thermoplastic components described herein can, in certain examples, be used to form a wheel component, such as a wheel used for a bicycle. The reinforced thermoplastic material can be used to form a completely continuous circular component that forms a wheel. The wheel component, or other structure formed by the reinforced thermoplastic material, can be a substantially hollow structure. Disclosed herein are techniques for forming the wheel component using one or more reinforced thermoplastic materials to form the wheel component having the hollow interior and a curved outer surface, including where the wheel component has a substantially circular hollow cavity and a continuous circular outer shape. 
     In one example, a wheel component is disclosed. The wheel component includes a rim bed portion defining an outer annular surface of the wheel component that is configured to engage a bicycle tire. The wheel component further includes a main structure portion defining a cavity with the rim bed portion. The rim bed portion and main structure portion are each formed from a reinforced thermoplastic material. The rim bed portion and the main structure are bonded to one another to form an integral structure. 
     In another example, the main structure portion can include a wall portion formed from the reinforced thermoplastic material. The reinforced thermoplastic material of the wall portion can include a plurality of plies overlapping one another and defining a radial crossply. The plurality of plies can include a first ply having a first edge. The first edge can define a bias angle of between 22.5 and 75 degrees from a center axis of a continuous circle defined by the outer annular surface. 
     In another example, the plurality of plies can include a second ply having a second edge. The second ply can overlap the first ply with the first and second edges being substantially transverse to one another. In some examples, the first and second plies can define an arrangement of plies. The wheel component can further include a plurality of the arrangement of plies disposed in a radial pattern to define the wall portion. 
     In another example, the rim bed portion and main structure portion can be at least one of thermally bonded, chemically bonded, or adhesively bonded. 
     In another example, the main structure portion can define an inner annular surface of the wheel component that is configured to receive a series of spokes. The main structure portion can be configured to withstand a pull force associated with the series of spokes of at least 300 lbs. The main structure portion can define a reinforcing layer along the inner annular surface. 
     In another example, the reinforced thermoplastic material includes a thermoplastic material and fibers held within the thermoplastic material. The fibers can include one or more of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers. In some examples, the fibers can define at least 30% of a volume of the reinforced thermoplastic material. 
     In another example, a wheel component is disclosed. The wheel component can include a continuous reinforced thermoplastic material and can have a rim bed portion and a main structure portion connected to the rim bed portion. The continuous reinforced thermoplastic material defines a circular cavity therethrough. External surfaces of the wheel component can be defined by the rim bed portion and the main structure portion can be free of indicia associated with a bladder exit from the cavity. 
     In another example, the indicia can include through portions of the wheel component extending between the circular cavity and an external environment that have a cross-dimension of greater than 15 mm. Further, the external surfaces can cooperate to completely seal the circular cavity from the external environment. The continuous reinforced thermoplastic material can include a layup of reinforced thermoplastic sections overlapping one another to define a radial crossply. The radial crossply can extend along a sidewall of the main structure portion. 
     In another example, the circular cavity can be formed by maintaining a pressurized region between the rim bed portion and the main structure portion during a thermal bonding process. The pressurized region can be maintained without an internal bladder, thereby allowing the external surfaces of the rim bed portion and the main structure portion to be free of the indicia typically associated with bladder exit from the cavity. 
     In another example, the circular cavity is self-sealing. The continuous reinforced thermoplastic material can exhibit a flexural strength of at least 740 MPa. 
     In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes forming a rim bed portion from a first reinforced thermoplastic material. The method further includes forming a main structure portion from a second reinforced thermoplastic material. The method further includes forming the fully reinforced thermoplastic wheel component as a continuous circular component by thermally bonding the rim bed portion and the main structure portion to one another within a tooling compartment. 
     In another example, forming the main structure can include defining a radial crossply by arranging a first ply of the second reinforced thermoplastic material relative to a second ply of the second reinforced thermoplastic material. One or both of the first or second plies defines a bias angle relative to a center axis of between 22.5 and 75 degrees. The forming of the main structure portion can include stamping the second reinforced thermoplastic material to define an inner annular surface configured for association with a series of spokes. 
     In another example, the operation of forming the fully reinforced thermoplastic wheel component can include heating the first and second reinforced thermoplastic materials above a melting temperature. Forming the fully reinforced thermoplastic wheel component can further include defining a cavity between the rim bed portion and the main structure portion by pressurizing a region of the tooling compartment substantially between the rim bed portion and the main structure portion. 
     In another example, a wheel component is disclosed. The wheel component includes a rim bed portion defining an outer annular surface of the wheel component that is configured to engage a bicycle tire. The wheel component further includes a main structure portion defining a cavity with the rim bed portion. The rim bed portion and the main structure portion are each formed from a reinforced thermoplastic material. Further, the rim bed portion and the main structure are thermally bonded to one another to form an integral structure. 
     In another example, the main structure portion can define an inner annular surface of the wheel component that can be configured to receive a series of spokes. The series of spokes can be engaged with the main structure portion to exhibit a pull force from the wheel component of at least 300 lbs. Additionally or alternatively, the series of spokes can be engaged with the main structure portion to exhibit a pull force from the wheel component of at least 400 lbs. Additionally or alternatively, the series of spokes can be engaged with the main structure portion to exhibit a pull force from the wheel component of at least 500 lbs. 
     In another example, the rim bed portion can be seated at least partially within the main structure portion. In some cases, the main structure portion includes a first wall portion and a second wall portion. The cavity can at least partially be defined by each of the rim bed portion, the first wall portion, and the second wall portion. The first wall portion and the second wall portion can be connected to one another via a lap joint. Additionally or alternatively, the second wall portion can define a reinforcing layer along an annular surface defined by the first wall portion. In some examples, the main structure portion can further include a third wall portion. In this regard, the cavity can be defined by each of the rim bed portion, the first wall portion, the second wall portion, and the third wall portion. 
     In another example, the rim bed portion includes a first rim wall portion and a second rim wall portion. The cavity can at least partially be defined by each of the first rim wall portion, the second rim wall portion, and the main structure portion. 
     In another example, the integral structure can define a continuous circular shape. 
     In another example, the reinforced thermoplastic material can include a thermoplastic material. The reinforced thermoplastic material can also include fibers held within the thermoplastic material. The fibers can include one or more of carbon fibers, glass fibers, Kevlar fibers, and/or basalt fibers. In some examples, the fibers can define at least 40% of a volume of the reinforced thermoplastic material. Additionally or alternatively, the fibers can define at least 70% of the volume of the reinforced thermoplastic material. The reinforced thermoplastic material can also include resin-impregnated spread carbon fiber tows, in certain applications. 
     In another example, the wheel component further includes a spoke portion formed from a reinforced thermoplastic material. The spoke portion can be thermally bonded with the main structure portion to form the integral structure as including each of the rim bed portion, the main structure portion, and the spoke portion. In this regard, the wheel component can further include a hub portion formed from a thermoplastic material. The hub portion can be thermally bonded with the spoke portion to form the integral structure including each of the rim bed portion, the main structure portion, the spoke portion, and the hub portion. While many shapes are possible and described herein, in some examples, the integral structure can define a tri-spoke shape. 
     In another example, a wheel component is disclosed. The wheel component includes a continuous reinforced thermoplastic material having a rim bed portion and a main structure portion connected to the rim bed portion. The continuous reinforced thermoplastic material defines a circular cavity therethrough. External surfaces of the wheel component are defined by the rim bed portion and the main structure portion, and are free of indicia associated with a bladder exit from the cavity. 
     In another example, the indicia can include through portions of the wheel component that extend between the circular cavity and an external environment, and that have a cross-dimension of greater than 20 mm. Additionally or alternatively, the indicia can include through portions of the wheel component that extend between the circular cavity and the external environment, and that have a cross-dimension of greater than 10 mm. The external surfaces cooperate to completely seal the circular cavity from the external environment. 
     In another example, the circular cavity can be formed by maintaining a pressurized region between the rim bed portion and the main structure portion during a thermal bonding process. The pressurized region can be maintained without an internal bladder, thereby allowing the external surfaces of the rim bed portion and the main structure portion to be free of the indicia associated with a bladder exit from the cavity. 
     In another example, a portion of an inflation component can be within the circular cavity and thermally bonded to the main structure portion. The portion of the inflation component can have a melt temperature that is higher than a melt temperature of the main structure portion. The portion of the inflation component can have a melt temperature that can be higher than the main structure portion and a melt temperature of the rim bed portion. 
     In another example, the wheel component can include a film within the circular cavity. The film can be adapted to define a self-sealing permanent bladder within the circular cavity. In some examples, the film can be formed from a nylon material. The film can have a melt temperature that can be higher than the melt temperature of one or both of the main structure portion or the rim bed portion. 
     In another example, the main structure portion can define a reinforced region along an inner annular region of the wheel component. The reinforced region can include multiple reinforced thermoplastic layers, thermally bonded to one another. The main structure portion can include a first wall portion and a second wall portion, each overlapping along the inner annular region. In some examples, the reinforced region is configured to establish a spoke pull force of at least 500 lbs. 
     In another example, the continuous reinforced thermoplastic material includes fiber filaments suspended in a resin matrix. The fiber filaments can be arranged in a compacted configuration adjacent one another within the resin matrix. The continuous reinforced thermoplastic material includes a nano coating therein surrounding fiber filaments for binding the filaments to the resin matrix. While many materials are possible, the fiber filaments can include one or more of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers. In some examples, the continuous reinforced thermoplastic material can exhibit a flexural strength of at least 740 MPa. 
     In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes arranging a rim bed portion and a main structure portion within a tooling compartment. The rim bed portion and the main structure portion are formed from a reinforced thermoplastic material. The method further includes pressurizing a region of the compartment that is between the rim bed portion and the main structure portion. The method further includes bonding the rim bed portion and the main structure portion by heating the reinforced thermoplastic material above a melting temperature. The method further includes sealing a cavity defined by the rim bed portion and the main structure portion. 
     In another example, the operation of heating includes exposing the tooling compartment to a heat source exhibiting a temperature of at least 450 degree F. The operation of arranging a rim bed portion and a main structure portion within a tooling compartment can include sealing the rim bed portion at least partially within the main structure portion. 
     In another example, the main structure portion can include a first wall portion and a second wall portion. In this regard, the operation of arranging can include overlapping the first wall portion and the second wall portion along an inner annular surface of the wheel component. In some examples, the operation of arranging can include mechanically engaging each of the first wall portion with a first side of the rim bed portion, and the second wall portion with a second side of the rim bed portion opposite the first side of the rim bed portion. Further, the operation of bonding can include defining an edge joint along the mechanical engagement of each of the first wall portion and the first side of the rim bed portion, and the second wall portion and the second side of the rim bed portion. 
     In another example, the operation of pressurizing includes delivering a pressurized fluid into the region of the compartment between the rim bed portion and the main structure portion. The pressurized fluid can be configured to maintain the region at a pressure of greater than 40 psi. The pressurized fluid can include compressed air. 
     In one example, the operation of pressurizing includes maintaining a contour of the region of the compartment that is between the rim bed portion and the main structure portion with a sacrificial material to define the cavity. In this regard, the operation of sealing can include allowing the reinforced thermoplastic material to close on itself at a point of entry for the pressurized fluid delivery. In some examples, the method further includes plying a higher-melt temperature material to one or both of the rim bed portion or the main structure portion, prior to the operation of arranging. The higher-melt temperature material can be a film plied to a consolidated panel or stamp form shape of one or both of the rim bed portion or the main structure portion. 
     In another example, the operation of pressurizing can include at least partially inserting a portion of the inflation component into the region of the compartment between the rim bed portion and the main structure portion. The portion of the inflation component can include a consumable adapted to seal the point of entry for the pressurized fluid delivery. Further, the portion of the inflation component can also include a thermoplastic material having a melt temperature that is higher than a melt-temperature of the reinforced thermoplastic material used to form the rim bed portion or the main structure portion. In some examples, the operation of sealing can include sealing a thermoplastic plug at the point of entry. 
     In one example, the operation of bonding defines an integral structure from the rim bed portion and the main structure portion. The integral structure can be a continuous circular structure. 
     In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method can include forming a rim bed portion from a first reinforced thermoplastic material, forming a main structure portion from a second reinforced thermoplastic material, and forming the fully reinforced thermoplastic wheel component as a continuous circular component by thermally bonding the rim bed portion and the main structure portion to one another within a tooling compartment. 
     In another example, the operation of forming the rim bed portion can include stamping the first reinforced thermoplastic material to define an external annular surface configured to engage a bicycle tire. The operation of forming the main structure portion can include stamping the second reinforced thermoplastic material to define an inner annular surface configured for association with a series of spokes. 
     In another example, the method can further include providing the first reinforced thermoplastic material and the second reinforced thermoplastic material from a common reinforced thermoplastic material having fiber tows arranged within a resin material. The fiber tows can be compacted relative to one another within the resin material. In some examples, the fiber tows can be arranged as a matrix having a width substantially larger than a height, the matrix defining a spread tow. 
     In another example, the operation of forming the fully reinforced thermoplastic wheel component can include heating the first and second reinforced thermoplastic materials above a melting temperature. Further, the operation of forming the fully reinforced thermoplastic wheel component can include defining a cavity between the rim bed portion and the main structure portion by pressurizing a region of the tooling compartment substantially between the rim bed portion and the main structure portion. Further, the operation of forming the fully reinforced thermoplastic wheel component can include arranging the rim bed portion, the main structure portion, and a sacrificial bladder in the tooling compartment, the sacrificial bladder configured to maintain a pressure in the region of at least 40 psi. In this regard, the method can further include removing the sacrificial bladder through at least one of the rim bed portion or the main structure portion. 
     In another example, the operation of forming the fully reinforced thermoplastic wheel component can include reinforcing an inner annular surface of the continuous circular component. The method can further include associating a series of spokes with the inner annular surface. In some examples, the reinforced inner annular surface and the series of spokes cooperate to exhibit a pull force of at least 500 lbs. 
     In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes plying a film to a reinforced thermoplastic material. The film has a higher melting temperature than that of the reinforced thermoplastic material. The method further includes defining a cavity with the reinforced thermoplastic material and plied film. The method further includes sealing the cavity using the film. 
     In another example, the reinforced thermoplastic material can include a consolidated panel or a stamp form shape of a rim bed portion or a main structure portion. The rim bed portion and the main structure portion can be arranged to form the fully reinforced thermoplastic wheel component. In this regard, the method can further include stamping the consolidated panel and the plied film to form the stamp form shape of the rim bed portion or the main structure portion. 
     In another example, the operation of sealing can include allowing a point of entry for pressurized fluid to close itself, using the film. In this regard, the method can further include pressurizing the cavity by at least partially inserting an inflation component through the point of entry. In some examples, the inflation component can be configured to maintain a pressure within the cavity of at least 40 psi. The operation of defining can include subjecting the reinforced thermoplastic material to a thermal bonding process to form an integral structure defining the wheel component. 
     In another example, the integral structure can be a continuous circular component. The reinforced thermoplastic material can include reinforcement fibers, including one or more of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers. 
     In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes arranging a rim bed portion and a main structure portion to define a cavity of the fully reinforced thermoplastic wheel component. The method further includes pressurizing the cavity by at least partially inserting an inflation component into the cavity. The inflation component is at least partially formed from a material having a melting temperature greater than a melting temperature of materials used to form the rim bed portion and the main structure portion. The method further includes sealing the cavity using the inflation component. 
     In another example, the operation of sealing can include defining a point of entry into the cavity for insertion of a portion of the inflation component. The point of entry can be defined through an annular surface defined by the rim bed portion. The operation of sealing can include co-curing the portion of the inflation component to the main structure portion. 
     In another example, the method further includes severing a portion of the inflation component from a remainder of the inflation component, the portion of the inflation component remaining at least partially within the cavity. The operation of sealing can include using the portion of the inflation component to close the cavity to an external environment. 
     In another example, the method further includes thermally bonding the rim bed portion and the main structure portion to one another. The thermal bonding can allow external surfaces of the wheel component to be formed free of indicia associated with bladder exit from the cavity, using a portion of the inflation component as a consumable within the cavity. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  depicts a sample bicycle; 
         FIG. 2  depicts detail  1 - 1  of a wheel assembly of  FIG. 1 ; 
         FIG. 3A  depicts a reinforced thermoplastic rim formed as an integral circular structure; 
         FIG. 3B  depicts a cross-sectional view of a reinforced thermoplastic material of  FIG. 3A  used to form the fully thermoplastic rim, taken along line  3 B- 3 B of  FIG. 3A ; 
         FIG. 4  depicts an example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 5A  depicts another example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 5B  depicts another example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 5C  depicts another example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 6  depicts another example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 7A  depicts an operation of forming a rim bed portion of a wheel component; 
         FIG. 7B  depicts an operation of forming a main structure portion of a wheel component; 
         FIG. 7C  depicts another operation of forming a main structure portion of a wheel component; 
         FIG. 7D  depicts an operation of plying a higher melt temperature film to a stamp-formed shape of a wheel component; 
         FIG. 7E  depicts an operation of plying a higher melt temperature film to a consolidated panel prior to a stamping operation; 
         FIG. 8A  depicts an example layup for manufacturing a radial crossply of a reinforced thermoplastic component; 
         FIG. 8B  depicts a wall portion of a wheel component having a radial crossply; 
         FIG. 9A  depicts another example layup for manufacturing a radial crossply of a reinforced thermoplastic component; 
         FIG. 9B  depicts another example layup for manufacturing a radial crossply of a reinforced thermoplastic component; 
         FIG. 9C  depicts another example layup for manufacturing a radial crossply of a reinforced thermoplastic component; 
         FIG. 9D  depicts another example layup for manufacturing a radial crossply of a reinforced thermoplastic component; 
         FIG. 10A  depicts a collection of components used to form a wheel component fully from a reinforced thermoplastic material; 
         FIG. 10B  depicts an assembly for thermally bonding reinforced thermoplastic components to form a wheel component; 
         FIG. 10C  depicts another assembly for thermally bonding other reinforced thermoplastic components to form another example of a wheel component; 
         FIG. 11  depicts a cross-sectional view of the assembly of  FIG. 10 , taken along line  11 - 11  of  FIG. 10C ; 
         FIG. 12  depicts an arrangement for pressurizing a cavity of a wheel component with a consumable inflation component; 
         FIG. 13  depicts a cross-sectional view of the assembly of  FIG. 12 , taken along line  13 - 13  of  FIG. 12 ; 
         FIG. 14  depicts another assembly for forming a continuous circular contour of a wheel component; 
         FIG. 15A  depicts a cross-sectional view of an example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 15B  depicts an exploded view of the wheel component of  FIG. 15A ; 
         FIG. 16A  depicts a cross-sectional view of another example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 16B  depicts an exploded view of the wheel component of  FIG. 16A ; 
         FIG. 17A  depicts a cross-sectional view of another example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 17B  depicts an exploded view of the wheel component of  FIG. 17A ; 
         FIG. 18A  depicts a cross-sectional view of another example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 18B  depicts an exploded view of the wheel component of  FIG. 18A ; 
         FIG. 19A  depicts a cross-sectional view of another example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 19B  depicts an exploded view of the wheel component of  FIG. 19A ; 
         FIG. 20A  depicts a cross-sectional view of another example of a wheel component formed from a reinforced thermoplastic material and having thermally bonded joints; 
         FIG. 20B  depicts an exploded view of the wheel component of  FIG. 20A ; 
         FIG. 21A  depicts an arrangement for performing a spoke weld for a reinforced thermoplastic wheel component, according to one example; 
         FIG. 21B  depicts an arrangement for performing a channel weld for the reinforced thermoplastic wheel component of  FIG. 21A ; 
         FIG. 22A  depicts an arrangement for performing a spoke weld for a reinforced thermoplastic wheel component, according to another example; 
         FIG. 22B  depicts an arrangement for performing a channel weld for the reinforced thermoplastic wheel component of  FIG. 22A ; 
         FIG. 23A  depicts an arrangement for performing a spoke weld for a reinforced thermoplastic wheel component, according to another example; 
         FIG. 23B  depicts an arrangement for performing a channel weld for the reinforced thermoplastic wheel component of  FIG. 23A ; 
         FIG. 24A  depicts an arrangement for performing a spoke weld for a reinforced thermoplastic wheel component, according to another example; 
         FIG. 24B  depicts an arrangement for performing a channel weld for the reinforced thermoplastic wheel component of  FIG. 24A ; 
         FIG. 25A  depicts an arrangement for performing a spoke weld for a reinforced thermoplastic wheel component, according to another example; 
         FIG. 25B  depicts an arrangement for performing a channel weld for the reinforced thermoplastic wheel component of  FIG. 25A ; 
         FIG. 26  depicts another example of a wheel component formed from a reinforced thermoplastic material; 
         FIG. 27A  depicts an apparatus including substantially hollow components that are formed from a thermoplastic material; 
         FIG. 27B  depicts a cross-sectional view of the substantially hollow components of  FIG. 27A , taken along line  27 B- 27 B of  FIG. 27A ; 
         FIG. 28  depicts a flow diagram of a method of manufacturing a fully reinforced thermoplastic wheel component; 
         FIG. 29  depicts a flow diagram of another method of manufacturing a fully reinforced thermoplastic wheel component; 
         FIG. 30  depicts a flow diagram of another method of manufacturing a fully thermoplastic wheel component; 
         FIG. 31  depicts a flow diagram of another method of manufacturing a fully thermoplastic wheel component; and 
         FIG. 32  depicts a flow diagram of a method of forming a sidewall of a fully thermoplastic wheel component. 
     
    
    
     The use of cross-hatching or shading in the accompanying figures is generally provided to clarify the boundaries between adjacent elements and also to facilitate legibility of the figures. Accordingly, neither the presence nor the absence of cross-hatching or shading conveys or indicates any preference or requirement for particular materials, material properties, element proportions, element dimensions, commonalities of similarly illustrated elements, or any other characteristic, attribute, or property for any element illustrated in the accompanying figures. 
     Additionally, it should be understood that the proportions and dimensions (either relative or absolute) of the various features and elements (and collections and groupings thereof) and the boundaries, separations, and positional relationships presented therebetween, are provided in the accompanying figures merely to facilitate an understanding of the various examples described herein and, accordingly, may not necessarily be presented or illustrated to scale, and are not intended to indicate any preference or requirement for an illustrated example to the exclusion of examples described with reference thereto. 
     DETAILED DESCRIPTION 
     The description that follows includes sample systems, methods, and apparatuses that embody various elements of the present disclosure. However, it should be understood that the described disclosure may be practiced in a variety of forms in addition to those described herein. 
     The present disclosure describes systems, devices, and techniques related to reinforced thermoplastic components. More specifically, the present disclosure describes using reinforced thermoplastic materials to form complex shapes, including shapes having contoured or curved surfaces, and/or shapes having a substantially hollow interior. As used herein, “reinforced thermoplastic materials” can include a variety of materials having reinforcement “fibers” held within a thermoplastic material. As described in greater detail below, this can include, by way of non-limiting example, certain resin-type or other thermoplastic materials that are impregnated with reinforcement fibers, including carbon fibers, glass fibers, Kevlar fibers, and/or basalt fibers, among other options described and contemplated herein. Thermoplastic materials can exhibit a superior strength-to-weight ratio, and are generally adaptable to a variety of application-specific shapes. Shapes that have a curved or circular contour and/or a hollow interior can often benefit from the strength-to-weight ratio of reinforced thermoplastic materials. Such constructions, however, can be hindered by traditional manufacturing techniques. 
     The systems and techniques of the present disclosure can mitigate such hindrances and produce reinforced thermoplastic components having substantially smooth, seamless, and consistently curved surfaces. Further, the systems and techniques of the present disclosure can produce reinforced thermoplastic components having a substantially hollow interior. The substantially smooth, seamless, and consistently curved surfaces, enhanced by the substantially hollow interior can facilitate the manufacturing of a wheel component formed from reinforced thermoplastic materials. More specifically, the systems and techniques herein can be adapted to facilitate the manufacturing of a wheel component fully from the reinforced thermoplastic materials, substantially free from other filler or support-type materials. 
     The reinforced thermoplastic material can be used to form an integral structure. An integral structure can be defined as a one-piece structure. The integral structure or one-piece or continuous structure can define a continuous circular shape or a segment thereof. The integral structure can thus can adapted to from a bicycle rim, as described in greater detail below. The fully reinforced thermoplastic material can provide a reduced-weight ratio while exhibiting enhanced strength that can be tailored for high-performance applications. For example, the continuous circular structure formed fully from the reinforced thermoplastic material can be tuned to withstand a pull force of a spoke of an associated series of spokes of at least 300 lbs., of at least 400 lbs., of at least 500 lbs., or greater as may be appropriate for a given application. The continuous circular structure can also be substantially free of indicia or seams or other markings of manufacture, such as that from the removal of a bladder of other sacrificial material from the hollow interior. This can provide an aesthetically pleasing finish to the wheel component, in addition to supporting overall performance, for example, by reducing possible failure mechanisms along the wheel component, such as where a rim bed and channel wall would typically meet. 
     While many structural implementations of the wheel component are possible and described herein, in one example, the wheel component includes a rim bed portion that defines an outer annular surface of the wheel component. The outer annular surface is shaped in a manner by which to engage a bicycle tire, including being substantially circular or defining a segment of a curve that is adapted to grip an outer tire or wheel component. The wheel component can further include a main structure portion that defines a cavity with the rim bed portion. The main structure portion can be a structural portion of the wheel component that is used, for example, to engage a series of spokes of the wheel component of other features that support the wheel component in operation. In some cases, the rim bed portion and the main structure component can one or both define a collection of walls or other features that are engageable with one another to form the wheel component, as presented herein. 
     Broadly, each of the rim bed portion and the main structure are formed from a reinforced thermoplastic material. Where the rim bed portion and/or the main structure include a collection of walls or associated components, all such components are also formed from a reinforced thermoplastic material. In this regard, the wheel component can be formed as a fully reinforced thermoplastic wheel component. Thermoplastic materials can be impregnated or more generally combined with reinforcement fibers to define the reinforced thermoplastic materials, which can have a fiber reinforcement of at least 30%, of at least 40%, or of at least 70% by volume. In certain examples, the reinforcement fibers can be strategically arranged within the thermoplastic material. For example, the reinforcement fibers can be subjected to a spread treatment during manufacture, or other elongation and orientation technique that allows the reinforced thermoplastic material to define a spread tow, such as a spread carbon fiber tow when carbon is used as a reinforcement fiber. Other techniques and modifications to the reinforced thermoplastic materials can be used, including arranging the reinforcement fibers in a matrix, such as in a compacted arrangement. Further, coatings or other treatments can be applied to fibers prior to (or during) integration with the thermoplastic material to form the reinforced thermoplastic material. This can be a nano-coating that surrounds some or all of the fibers, such as surrounding some or all of individual fibers to define a barrier between the fibers and the surrounding thermoplastic material. 
     In one example, a reinforced thermoplastic material can be used to form a wall portion of the main structure of the wheel component. The wall portion can be formed from a reinforced thermoplastic material that is constructed from a plurality of plies of reinforced thermoplastic material, such as any of the thermoplastic materials described herein. The plies can be arranged to overlap one another and collectively form a radial pattern to define the wall portion. To illustrate, the radial pattern can include a first ply have a first edge and a second ply having a second edge. The first and second plies can overlap one another, such as overlapping the first and the second plies such that the second edge is arranged substantially transverse to the first edge. Further, the first and second plies can be arranged such that at least one of the first and second edges defines a bias angle relative to a center axis of a continuous circle defined by the wheel. Sample bias angles can be between substantially 22.5 and 75 degrees, such as being substantially between 40 and 60 degrees, such as being preferably about 45 degrees. The bias angle can be tuned in order to optimize wall strength, as described herein. The first and second plies can be overlapped with one another to define an arrangement or grouping of plies. The wall portion can include a plurality of arrangement of plies in order to define the radial crossply pattern. The wall portion can include multiple layers of crossply laminate, including a 6 layer crossply laminate, with 12, 22, or more overlapping course of tape, as one illustration. 
     The reinforced thermoplastic materials used to form the wheel component can be associated with one another to form an integral structure. As one example, a first reinforced thermoplastic material can be used to form a rim bed portion of the wheel component and a second reinforced thermoplastic material can be used to form the main structure portion of the wheel component. In certain examples, the first and/or second reinforced thermoplastic materials can be a sheet, tape, panel, or other largely undefined or even partially flexible form. The reinforced thermoplastic materials can be subjected to one or more machine processes in order to define the rim bed portion and/or the main structure portion and/or other pieces of the wheel component or complex-geometry components of the present disclosure. For example and as described in greater detail below, the reinforced thermoplastic materials can be subjected to stamping processes in order to define a stamp-formed shape of the rim bed portion, the main structure portion, and/or other portions of the wheel component or other shapes. The stamp form shape can generally define application-specific geometries of the rim bed portion or the main structure portion, including geometries adapted to use with a bicycle including the outer annular surface adapted to engage a bicycle tire and an inner annular surface configured to engage a series of spokes of the wheel component. 
     Thermal bonding can be used to join the rim bed portion and main structure portion to one another in order to form the wheel component as an integral structure. The integral structure can be a one-piece structure. In one example, the rim bed portion and the main structure portion can generally be arranged in a tooling or mold that roughly defines a target shape of the wheel component. The tooling can be subjected to heat, including subjecting the tooling to heat in excess of 450 degrees F.; however, in other cases, the temperature can be more or less than 450 degree F. based on the particular composition of the reinforced thermoplastic material. When exposed to such heat, the thermoplastic material softens and transitions toward a melted or partially melted state. The thermoplastic material of each of the rim bed portion and the main structure portion transitions toward this state within the tooling, where the portions are generally adjacent or contacting one another. For example, the rim bed portion and the main structure portion can be mechanically engaged with one another and/or pressed against a surface of one another in the tooling, such as in a tooling compartment. In this regard, upon transitioning toward and into the partially melted state, the reinforced thermoplastic material of the each of the rim bed portion and the main structure can generally join with one another. For example, the thermoplastic material of the rim bed portion and the thermoplastic material of the main structure portion can at least partially combine or intermix as each approaches or enters a partially melted or fully melted state. The reinforced thermoplastic materials can be subsequently cooled, as described herein, allowing each to return to a more solidified state as a single, integrally formed component from the rim bed portion and the main structure portion. For example, the reinforced thermoplastic material can be cooled to define an integral structure. This can allow different components or portions of the rim (e.g., the rim bed, wall portion, etc.) to collectively define a one-piece, or continuous, and/or seamless structure after formation. 
     The thermal bonding process can also be associated with defining a substantially hollow cavity within the wheel component. The wheel component can have a substantially hollow cavity to reduce weight and improve stability of the wheel. It is also possible to form a wheel as a substantially solid structure, such as may be the case for a wheel used in jogging strollers, carts, luggage, or other applications. Where the wheel component includes the substantially hollow cavity, the systems and techniques of the present disclosure include establishing and maintaining a shape of the cavity during the thermal bonding process. This allows the reinforced thermoplastic material to transition toward and into a partially melted or melted state without collapsing or deforming in a manner that would detract from the formation of an internal cavity. Maintaining the shape of the cavity can also facilitate the joining of the reinforced thermoplastic material, for example, by allowing the rim bed portion and the main structure portion to be pressed to together with a sufficient external force to facilitate the general intermixing or combination of the various reinforced thermoplastic materials without such external force distributing the shape of the cavity. Rather, with the shape of the cavity maintained, the external force of the tooling can also facilitate forming the cavity shape. For example, the rim bed portion and/or the main structure portion can be pressed or manipulated in a manner relative to or against a sacrificial bladder in order to use the partially melted or melted form of the reinforced thermoplastic material to establish the internal cavity shape of the wheel component, as one example. 
     In this regard, in some examples, the sacrificial bladder can be used to facilitate forming the internal cavity of the wheel component during thermal bonding. For example, a substantially solid material, including certain industrial foams and fillers or consolidated materials can be shaped to define a contour of the internal cavity. Additionally or alternatively, an inflatable bladder can be used, such as an assembly that can maintain a pressurized region between the main structure portion and the rim bed portion during the thermal bonding process. The rim bed portion and the main structure portion can be associated with the sacrificial bladder within the tooling assembly prior to the thermal bonding. The sacrificial bladder can be largely heat resistant and/or have a melting temperature above, or substantially above, that of the heat to which the tooling is subject during the thermal bonding process. In this regard, the sacrificial bladder can retain a solid shape, such as not being melted or partially melted, while the reinforced thermoplastic material of the rim bed portion and the main structure portion are melted or partially melted. The rim bed portion and the main structure portion can therefore be joined together, as described herein, without collapsing or deforming into an internal cavity defined by the respective portions. The rim bed portion and the main structure portion can also be joined together without also being inadvertently joined to the sacrificial bladder. 
     Subsequent to cooling, the sacrificial bladder can be removed from the wheel component, defining the substantially hollow cavity within the wheel component. Where the wheel component is a segment of a wheel, the sacrificial bladder can be removed from a side of the wheel component. Additionally or alternatively, the sacrificial bladder can be removed from a fully formed continuous and enclosed circular component. For example, it can be desirable for the sacrificial bladder to remain within the wheel segment throughout the formation of multiple wheel component segments to form the wheel component, which can have a continuous, integral structure that defines a circular shape. Further, the rim bed portion and the main structure portion can be joined to one another as a continuous and enclosed circular component, largely leaving the sacrificial bladder in the wheel component. In this regard, the sacrificial bladder can be removed via a port or hole that can generally be machined through one or both of the rim bed portion or the main structure portion. Subsequent operations can be used to cover or seal the port or hole and enclose the continuous circular cavity, as may be appropriate for a given application. 
     The systems and techniques described can also be adapted to maintain and/or establish the internal cavity substantially without the use of a sacrificial bladder. Broadly, the systems and techniques described herein can be used to pressurize a region of a tooling compartment that is holding the rim bed portion and the main structure during a thermal bonding process. For example, a fluid, such as compressed air, can be supplied to a region of the tooling compartment that is substantially between the rim bed portion and the main structure portion. The fluid can act to maintain a cavity between the rim bed portion and the main structure portion as the reinforced thermoplastic materials are bonded to one another. For example, an inflation component can extend partially into the cavity and supply the compressed air, which can be supplied with a pressure of at least 40 psi, of at least 100 psi, of at least 200 psi, or greater based on the material properties of the given application. The compressed air can pressurize the tooling compartment and at least partially hold the rim bed portion and the main structure portion at a desired arrangement within the tooling compartment. As the rim bed portion and the main structure portion begin to transition toward and into a partially melted or melted state, the pressure within the cavity can impede the thermoplastic material from deforming in a manner that would hinder or detract from a contour of the internal cavity. For example, the partially melted or melted reinforced thermoplastic material would be encouraged away from pressurized zone, and toward the tooling compartment boundaries and\or the respective rim bed portion and main structure portion for thermal bonding therebetween. 
     As described in greater detail herein, upon cooling, the inflation component can be removed from the internal cavity and the internal cavity can be substantially enclosed from an external environment. In some cases, this can involve using a plug or other thermoplastic material, which can be reinforced, to thermally bond with the rim bed portion and/or the main structure portion upon exit of the inflation component from the wheel component. Additionally or alternatively, the rim bed portion and/or the main structure portion can be substantially self-sealing, allowing the point of entry of the inflation component to generally close in on itself as the inflation component is removed. In certain examples, this can be facilitated by use of a high-melt temperature film that is plied to one or both of the reinforced thermoplastic material that forms the rim bed portion and/or the main structure portion. For example, the high-melt temperature film can be plied to a consolidated panel or the stamp form shape of the rim bed portion or the main structure portion, in certain examples. The film can have a melting temperature that is higher than that of the associated rim bed portion or the main structure portion. In this regard, upon removal of the inflation component, the associated rim bed portion or the main structure portion cools, and solidifies according to a different thermal profile than that of the film. The film can exhibit a more solid state than the associated rim bed portion or the main structure portion for a given temperature. The film can act as an internal barrier that guides the reinforced thermoplastic material along a path that closes and seals the point of entry for the inflation component. In certain other examples, as described herein, the inflation component itself can be used to seal the point of entry for the pressurized fluid delivery into the cavity. For example, at least a portion of the inflation component can be formed from a material having a higher melting temperature than that of the associated rim bed portion or the main structure portion. The portion can be a tip of the inflation component that is introduced in the cavity to supply the pressurize air. The tip can be a consumable feature of the inflation component. For example, subsequent to thermal boding of the rim bed portion and the main structure portion, the tip can be severed or otherwise removed from a remainder of the inflation component. The tip or consumable portion of the inflation component can in turn be used to seal the point of entry for the pressurized air. For example, the tip exhibits a higher melting temperature than the associated rim bed portion or the main structure portion, and thus cools and solidifies according to a different thermal profile. This different thermal profile acts to guide the associated rim bed portion or the main structure portion to close and seal the point of entry for the pressurized air. 
     With these and other techniques described herein, the resulting wheel component can include a substantially smooth outer contour that can be free of indicia associated with bladder exit from the internal cavity of the wheel component. For example, the finished wheel component can have an external surface that can be free of holes that are larger than 20 mm in cross-dimension, and/or free of holes that are larger 10 mm in cross-dimension. Such holes could be indications of bladder removal, whereas the absence of such holes can indicate a streamlined, bladderless manufacture of the hollow cavity, as described herein. 
     It will be appreciated that while the foregoing discussion includes reference to wheel components and other features related to bicycles, this is presented herein as an example implementation of the systems and techniques for forming intricate and optionally hollow structures fully from a reinforced thermoplastic material or materials. The systems and techniques provide substantial improvements to existing bicycle-related technology, for example, by enhancing the strength-to-weight ratio, by increasing the pull force capabilities of rim, adapting the rim to differentials in compressive and tensile stresses, and other improvements not realized by existing designs. As contemplated herein, the fully reinforced thermoplastic components can be adapted to a wide variety of structures and industries where high-performance is desired. In some cases, this can include adapting the reinforced thermoplastic material to other wheel-related applications, including wheel applications for strollers, carts, luggage, and other uses. For example, the reinforced thermoplastic material can be used to form a wheel having an integrally formed tri-spoke shape, which can optionally have an internal cavity. Other uses are contemplated, including using the reinforced thermoplastic material for applications with aerodynamic-specific shape requirements, such as a blade for a wind turbine or a hydrodynamic foil, as examples. Such applications can benefit from a sufficiently high strength-to-weight ratio, and often demand precise external contours, which the techniques of the present disclosure can provide. In other examples, other applications are contemplated herein with the scope of the present disclosure. 
     Reference will now be made to the accompanying drawings, which assist in illustrating various features of the present disclosure. The following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventive aspects to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the present inventive aspects. 
     As described herein, the reinforced thermoplastic structures can be adapted for use with a bicycle or other apparatus that uses wheels. In this regard,  FIG. 1  depicts a bicycle  100 . The bicycle  100  includes wheel assemblies  108  having a rim  112 . The rim  112  can be formed from a reinforced thermoplastic material, such as the reinforced thermoplastic materials generally discussed above and described in greater detail below. This rim  112  can be adapted to withstand dynamic conditions during use of the bicycle  100  by a rider, including compressive and tensile stresses at particular localized regions of the rim  112 . 
     As shown in  FIG. 1 , the composite rim  112  is engaged with a tire  116 . The tire  116  can be any appropriate component configured to engage and grip a riding surface to facilitate forward motion of the bicycle  100 , including slim profile tires. As described in greater detail below, the tires  116  can induce various maximum compressive stresses on the rim  112 . The rim  112  is associated with a series of spokes  114  that structurally connect the rim  112  to other components of the bicycle  100 . The series of spokes  114  can induce various maximum stresses on the rim  112 . 
     In the non-limiting example of  FIG. 1 , the wheel assembly  108  and rim  112  are shown with the bicycle  100 . However, it will be appreciated that the rim  112  can be used with a variety of bicycles and/or any suitable apparatuses that implement wheels for movement. This can include bicycles with an electric motor, strollers, carts, luggage, and so on. For purposes of illustration, the bicycle  100  is further shown as having a frame  104 , a fork  120 , a handle assembly  124 , a drive assembly  126 , pedals  128 , a chain  132 , a saddle  136 , and a seat post  140 . It should be noted that the bicycle  100  can include other components (or variations of the foregoing components), such as various derailleurs, heat sets, cassettes, brakes, frame tubes of various constructions, and so on. As such, the discussion of any bicycle, such as bicycle  100 , is meant as illustrative only. 
     With reference to  FIG. 2 , detail  1 - 1  of the wheel assembly  108  is shown.  FIG. 2  shows the rim  112  connected with the series of spokes  114  and engaged with the tire  116 . The tire  116  is shown contacting a riding surface  101 . The rim  112  is subjected to various dynamic conditions during use of the bicycle  100 . Not only do the location of forces received by the rim  112  change as the wheel assembly  108  rotates, the profile of the forces can be different as well. 
     In  FIG. 2 , the rim  112  is shown being subjected to a compressive force Fc and a tensile force F T . The compressive force Fc can result, for example, from the engagement of the tire  116  with the riding surface  101 . The tensile force F T  can result from the structural engagement defined by the series of spokes  114  with other components of the bicycle  100 . In other examples, the rim  112  is subjected to other forces, which can change based on the dynamic operating conditions of the bicycle  100 . 
     The rim  112  is formed fully from a reinforced thermoplastic material, such as from any of the reinforced thermoplastic materials described herein. The reinforced thermoplastic material can be specifically adapted to increase a strength-to-weight ratio of the rim  112 . This can enhance a performance of the rim by not only reducing the overall weight of the wheel assembly  108 , but also by selectively providing strength to the rim  112  in target regions. For example, the series of spokes  114  exert various forces on the rim  112  during use of the bicycle  100 . In one example, the rim  112  is adapted, via the reinforced thermoplastic materials, to withstand a pull force from one or more of the series of spokes  114  for high-performance operations. The pull force can be indicative of an amount of force exerted by the spoke on a portion of the rim bed, such as a portion where a spoke and the rim  112  are joined. For example, the rim  112  can be adapted to withstand a pull force of at least 300 lbs. from a spoke of the series of spokes  114 , of at least 400 lbs. from a spoke of the series of spokes  114 , of at least 500 lbs. from a spoke of the series of spokes  114 , or greater. 
       FIG. 3A  depicts a rim  300  formed fully from a reinforced thermoplastic material. The rim  300  can be an integral structure having a continuous circular contour  301 . The rim  300  can also be substantially hollow throughout the continuous circular cavity. The rim  300  can also have a substantially smooth, seamless exterior surface that is substantially free of any indicia of bladder exit from the internal cavity or other evidence of intermediate manufacturing processes. Such features cooperate to define an aesthetically pleasing finish the rim  300 . Additionally, such features can reduce potential failure mechanisms by providing a seamless finish, strengthened by the fibers of the reinforced thermoplastic material. 
     The rim  300  can include a rim bed portion  304  and a main structure portion  310 . The rim bed portion  304  and the main structure portion  310  can define an integral structure. For example, the rim bed portion  304  and the main structure portion  310  can collectively define a one-piece, or continuous, and/or seamless structure after formation. The rim bed portion  304  is generally configured to engage a bicycle tire. For example, the rim bed portion  304  can define an outer annular surface  306  that is adapted to receive and retain a bicycle tire. The main structure portion  310  is generally configured to define a channel of the rim  300  and is adapted to engage a series of spokes. For example, the main structure portion  310  can define an inner annular surface  312  that is adapted to engage a series of spokes  390 . The series of spokes  390  can be connected to a hub  392  or other feature. In this regard, the series of spokes  390  can exhibit a pull force on the main structure portion  310 . The main structure portion  310  can define a reinforced region  314 , in certain examples, where the series of spokes  390  and the main structure  310  engage one another. The reinforcement region  314  can be formed from additional reinforced thermoplastic materials, selectively providing increased strength and performance. 
     As shown in the detail view of  FIG. 3A , the rim bed portion  304  and the main structure portion  310 , while cooperating to define the integrally formed rim  300 , can be provided as two separate components during a manufacturing process. The rim bed portion  304  and the main structure portion  310  can be thermally bonded to one another generally along a thermally bonded interface  308 . The thermally bonded interface  308  is shown in the detail of  FIG. 3A  for purposes of illustration. It will be appreciated, however, that while the rim bed portion  304  and the main structure portion  310  are provided as individual components during the manufacturing process, the thermally bonding interface  308  can be substantially invisible to the naked eye in the final product, and as such, define a seamless interface or transition between the rim bed portion  304  and the main structure portion  310 . In this regard, the final rim  300  can have a seamless surface  302 . 
       FIG. 3B  depicts a cross-sectional view of the rim  300  of  FIG. 3A , taken along line  3 B- 3 B. More particularly,  FIG. 3B  shows a cross-sectional view of the reinforced thermoplastic material used to form the rim  300 . The rim  300  can be fully formed from the reinforced thermoplastic material. In this regard, the rim bed portion  304 , the main structure portion  310 , and/or any or all other portions of the rim  300  can be formed from the reinforced thermoplastic materials. It will therefore be appreciated that the following discussion of reinforced thermoplastic materials can be applicable to any or all components of the rim  300 , or more generally the wheel components and complex geometric structures described herein. 
       FIG. 3B  shows the cross-section of the rim  300  as being formed from a reinforced thermoplastic material  350 . The reinforced thermoplastic material  350  broadly includes reinforcement fibers  354  that are disposed in a thermoplastic material  358 . The thermoplastic material  358  is generally defined by a material that is softened through the application of heat and is conversely hardened when cooled. The thermoplastic material  358  can be heated and cooled multiple, sequential times without substantial degradation of material properties. Certain resins, polymers, synthetics, nylons, and/or other materials can be used. The reinforcement fibers  354  provide strength to the thermoplastic material  358 . For example, the fibers  354  can maintain the shape and physical state during the application of heat to the thermoplastic material  358 . Sample fibers include carbon fibers, glass fibers, Kevlar fibers, basalt fibers, and/or other appropriate materials that can be adapted to provide strength to the thermoplastic material  358 . In some cases, as shown in the detail of  FIG. 3B , the fibers  354 , individually or collectively, can be encased or partially encased in a coating  356 . The coating  356  can be a nano-coating that defines a barrier between the fibers  354  and the thermoplastic material  358 . 
     The reinforced thermoplastic material  350  can be manufactured in a variety of manners to increase the strength of the material via the arrangement of the fibers  354 . For example, in some cases, the fibers  354  can be subjected to a spread technique that establishes the fibers  354  in the thermoplastic material  358  as a spread tow. In certain cases, this can allow a given cross-section of the reinforced thermoplastic material  350  to have a width  370  that is greater than a height  368 . Additionally or alternatively, the spread technique or other manufacturing technique can arrange the fibers  354  in an elongated fashion. For example, the fiber  354  can be generally arranged substantially parallel to one another and elongated. Additionally or alternatively, the fibers  354  can define a compact arrangement  362  in the thermoplastic material  358 . The compact arrangement  362  can help organize the fibers  354  in a manner to increase a density of the fibers  354  in the reinforced thermoplastic material  350 , by volume. For example, for a representative volume  366  of the reinforced thermoplastic material  350 , the fibers  354  can define at least 40% of a volume of the material  350 , at least 70% of a volume of the material  350 , or other appropriate value based on the target strength and application. 
       FIGS. 4-6  depict sample constructions of wheel components of the present application. A wheel component can be a segment of a wheel or a continuous circular component.  FIGS. 4-6  depict various cross-sectional views of the wheel components. The wheel components of  FIG. 4-6  can be used to define any of the rims and wheel assemblies described herein, including the rim  112  of  FIGS. 1 and 2 , and the rim  300  of  FIGS. 3A and 3B . Further, it will be appreciated that  FIGS. 4-6  show the wheel component in a state prior to thermal bonding for purposes of illustrating the structural relationship of reinforced thermoplastic materials used to form the wheel component. Subsequent to a thermal bonding process, such as subsequent to any of thermal bonding processes described herein, the individual reinforced thermoplastic material can join to one another in a manner that forms the wheel component as single, integrally-formed structure. 
     With reference to  FIG. 4 , a cross-sectional view of a wheel component  400  is shown. The wheel component  400  can be formed fully from a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. 
     The wheel component  400  is shown in  FIG. 4  as including a rim bed portion  404  and a main structure portion  410 . The rim bed portion  404  and the main structure portion  410  cooperate to define a cavity  406 . The rim bed portion  404  can define an outer annular surface  408  that is adapted to engage a bicycle tire. The main structure portion  410  can define an inner annular surface  414  that is adapted to engage a series of spokes. The main structure portion  410  can optionally define a reinforcement region  414  along some or all of the inner annular surface  414 . The reinforcement region  416  can be an increased strength region of the main structure portion to facilitate increasing the strength to the wheel component  400 , such as providing a sufficiently high pull force, as described herein, for high-performance use. 
     The main structure portion  410  can include a first wall portion  412   a  and a second wall portion  412   b . In the example of  FIG. 4 , the first wall portion  412   a  and the second wall portion  412   b  are provided as a generally single form of reinforced thermoplastic material. The first and second wall portions  412   a ,  412   b  can have a thickness  492 . In some cases, the thickness  492  can be less than a thickness  490  of the rim bed portion  404 ; however, this is not required. The main structure portion  410  and the rim bed portion  404  can be joined to one another at an edge joint. In the arrangement of  FIG. 4 , the main structure portion  410  and the rim bed portion  404  can collectively define a thickness  494  at the edge. This increased thickness can provide stability to a bicycle tire engaged with the rim bed portion  404 . 
     With reference to  FIG. 5A , a cross-sectional view of a wheel component  500  is shown. The wheel component  500  can be formed fully from a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. The wheel component  500  can be substantially analogous to the wheel component  400  of  FIG. 4  and include: a rim bed portion  504 , a main structure portion  510 , a cavity  506 , an outer annular surface  508 , an inner annular surface  514 , a first wall portion  512   a , a second wall portion  512   b , a reinforced region  516 , a thickness  592 , a thickness  590 , and a thickness  594 , redundant explanation of which is omitted here for clarity. 
       FIG. 5A  further shows the first wall portion  512   a  and the second wall portion  512   b  as being defined by different pieces of reinforced thermoplastic material. The first wall portion  512   a  and the second wall portion  512   b  can define an overlap  530  at the reinforcement region  516 . The overlap  530  of the first wall portion  512   a  and the second wall portion  512   b  can enhance the strength of the wheel component  500  at the inner annular surface  514 . 
     Also shown in  FIG. 5A , the first wall portion  512   a  and the rim bed portion  504  can be joined to one another along a first ridge region  580 . For example, the first wall portion  512   a  can have an end  572  and the rim bed portion  504  can have an end  570 . The ends  570 ,  572  can be joined to one another using the techniques described herein to form the first ridge region  580 . Further, the second wall portion  512   b  and the rim bed portion  504  can be joined to one another along a second ridge region  582 . For example, the second wall portion  512   b  can have an end  573  and the rim bed portion  504  can have an end  571 . The ends  571 ,  573  can be joined to one another using the techniques described herein to form the second ridge region  582 . The first and second ridge regions can cooperate to receive a bicycle tire therebetween. In the embodiment of  FIG. 5A , the ends  570 ,  572  are arranged substantially parallel to one another, and with a terminal point of each of respective ends  570 ,  572  substantially unobstructed by the respective one of the first wall portion  512   a  or the rim bed portion  504 . Further, the ends  571 ,  573  are arranged substantially parallel to one another, and with a terminal point of each of the respective ends  571 ,  573  substantially unobstructed by the respective one of the second wall portion  512   b  or the rim bed portion  504 . 
     In some cases, the ends  570 ,  571  of the rim bed portion  504  can wrap around the respective ends of the first and second wall portions. For example and with reference to  FIG. 5B , the end  570  of the rim bed portion  504  wraps at least partially around the end  572  of the first wall portion  512   a . As further shown in  FIG. 5B , the end  571  of the rim bed portion  504  warps at least partially around the end  573  of the second wall portion  512   b . Accordingly, the at least partial wrapping can help modify a performance characteristic of the first and second ridge regions  580 ,  582 , such as enhancing the strength of these regions or otherwise tailoring the regions for use in particular applications. 
     In some cases, ends  572 ,  573  can wrap around the respective ends of the rim bed portion  504 . For example and with reference to  FIG. 5C , the end  572  of the first wall portion  512   a  wraps at least partially around the end  570  of the rim bed portion  504 . As further shown in  FIG. 5C , the end  573  of the second wall portion  512   b  wraps at least partially around the end  571  of the rim bed portion  504 . Accordingly, the at least partial wrapping can help modify a performance characteristic of the first and second ridge regions  580 ,  582 , such as enhancing the strength of these regions or otherwise tailoring the regions for use in particular applications. 
     With reference to  FIG. 6 , a cross-sectional view of a wheel component  600  is shown. The wheel component  600  can be formed fully from a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. The wheel component  600  can be substantially analogous to the wheel component  400  of  FIG. 4  and include: a rim bed portion  604 , a main structure portion  610 , a cavity  606 , an outer annular surface  608 , an inner annular surface  614 , a first wall portion  612   a , a second wall portion  612   b , a reinforced region  616 , an overlap  630 , a first ridge region  680 , an end  670 , an end  672 , a second ridge region  682 , an end  671 , an end  673 , a thickness  692 , a thickness  690 , and a thickness  694 , redundant explanation of which is omitted here for clarity. 
     Notwithstanding the foregoing similarities, the rim bed portion  604  is shown in  FIG. 6  as including a first rim bed portion  604   a  and a second rim bed portion  604   b . The first and second rim bed portions  604   a ,  604   b  can be layered or composite components or layers that are formed with one another in order to define the rim bed portion  604 . The dual layer configuration of  FIG. 6  can help reinforce the outer annular surface  608 . The thickness  690  can be defined as including a thickness of the first rim bed portion  604   a  and the second rim bed portion  604   b    
       FIGS. 7A-7E  depict various operations of manufacturing a formed shape of the reinforced thermoplastic material. The reinforced thermoplastic material can be initially manufactured as a sheet, a roll, a tape, panel, or the like. According to the techniques described herein, the reinforced thermoplastic material can be manipulated into a shape that is subsequently used to form the wheel component or other complex-geometry shape. For example, the reinforced thermoplastic material can be stamped or pressed into a shape in order to define a rim bed portion, a main structure portion, one or more wall portions, one or more reinforcement portions, and so on. The stamp-formed shape of these components can then be mechanically engaged with one another and subjected to a thermal bonding process to form the continuous integrally-formed circular structure of the wheel component. 
     With reference to  FIG. 7A , an operation  700   a  is shown. At the operation  700   a , a stamp form shape of a sample rim bed portion can be formed. For example, a reinforced thermoplastic material  708  can be provided substantially between a first stamp half  704  and a second stamp half  706 . The reinforced thermoplastic material  708  can be substantially analogous to any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. The first and second stamp halves  704 ,  706  can be advanced toward the reinforced thermoplastic material  708  in order to press the reinforced thermoplastic material  708  into the shape of a rim bed portion, such as that shown in  FIG. 7A . To facilitate the foregoing, the reinforced thermoplastic material  708  can be heated to encourage deformation into the stamp form shape defined by the first and second stamp halves  704 ,  706 . 
     With reference to  FIG. 7B , an operation  700   b  is shown. At the operation  700   b , a stamp form shape of a sample wall portion can be formed. For example, a reinforced thermoplastic material  718  can be provided substantially between a first stamp half  714  and a second stamp half  716 . The reinforced thermoplastic material  718  can be substantially analogous to any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. The first and second stamp halves  714 ,  716  can be advanced toward the reinforced thermoplastic material  718  in order to press the reinforced thermoplastic material  718  into the shape of a wall portion, such as that shown in  FIG. 7B . To facilitate the foregoing, the reinforced thermoplastic material  718  can be heated to encourage deformation into the stamp form shape defined by the first and second stamp halves  714 ,  716 . 
     With reference to  FIG. 7C , an operation  700   c  is shown. At the operation  700   c , a stamp form shape of another sample wall portion can be formed. For example, a reinforced thermoplastic material  728  can be provided substantially between a first stamp half  724  and a second stamp half  726 . The reinforced thermoplastic material  728  can be substantially analogous to any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. The first and second stamp halves  724 ,  726  can be advanced toward the reinforced thermoplastic material  728  in order to press the reinforced thermoplastic material  728  into the shape of a wall portion, such as that shown in  FIG. 7C , which can be a wall portion configured to corresponding engagement with the wall portion of  FIG. 7B . To facilitate the foregoing, the reinforced thermoplastic material  728  can be heated to encourage deformation into the stamp form shape defined by the first and second stamp halves  724 ,  726 . 
     In some cases, a film can be plied to the reinforced thermoplastic material to facilitate thermal bonding. For example, a film having a higher-melt temperature than the reinforced thermoplastic material can be plied into a stamp-form shape of one or more of the portions of the wheel component and/or a consolidated panel. The different thermal characteristics of the film can influence the behavior of the reinforced thermoplastic material as it begins to cool. For example and as described herein, the reinforced thermoplastic material can be influenced to seal or close a hole formed through the material, such as a hole used to provide pressurized air to an internal cavity. 
     For purposes of illustration,  FIG. 7D  shows an arrangement  750  having a film  754  being applied to a stamp form shape  762 . The stamp form shape  762  can be or define a portion of the rim bed portions or main structure portions described herein. The stamp form shape  762  can define a contour  766 . The film  764  can be arranged to match the contour  766 , and thus exhibit a contour  758  upon being plied with the stamp form shape  762 . 
       FIG. 7E  shows an arrangement  780  having a film  784  and a consolidated panel  792 . 
     The consolidated panel  792  can be a reinforced thermoplastic material, which can be presented in a state prior to stamping into one or more components of the various wheel assemblies described herein. The consolidated panel  792  can define a contour  796 , which can be substantially planar in some instances. The film  784  can be arranged to match the contour  796 , and thus exhibit a contour  788  upon being plied with the consolidated panel  792 . The plied consolidate panel  792  and the film  784  can in turn be introduced to a stamp or press to form the one or more components of the wheel assembly as a plied, optionally laminated structure, having the reinforced thermoplastic material and the plied higher-melt temperature film. 
     In some cases, the reinforced thermoplastic material can be formed from a plurality plies. The plies can be arranged relative to one another in order to define a layup or composite structure that can be used to form one or more portions of the wheel component. As one example, the wall portion of the wheel component can be formed from a plurality of plies of thermoplastic material. The plurality of plies can be arranged to overlap one another and collectively form a radial pattern to define the wall portion. One or more or all of the plurality of plies can be arranged or biased relative to a center axis of wheel component. For example, a given ply can have an edge that defines an angle with the center axis of between substantially 22.5 and 75 degrees, such as being substantially between 40 and 60 degrees, such as being preferably about 45 degrees. The bias angle can be tuned in order to optimize wall strength of the wall portion. 
     Turning to  FIG. 8A , a layup  800  is shown for forming the reinforced thermoplastic material from a plurality of plies. The layup  800  includes a radial pattern of plies  802 . The radial pattern of plies  802  is arranged about a wall portion outline  804 . The wall portion outline  804  can be generally indicative of a circular shape of the wheel component. In other examples, other outlines and shapes can be used to arrange the plurality of plies. The wall portion outline  804  is shown having a center  806 . The center  806  can define a center axis of the wall portion outline  804  and/or other generally circular component of the wheel component, including the outer annular surface. 
     The radial pattern of plies  802  is shown in  FIG. 8A  as including a first ply  810  and a second ply  820 . The first ply  810  includes a first edge  812 . The second ply  820  includes a second edge  822 . The first edge  812  can define an angle θ 1  from a center axis defined by the center  806 . The second edge  822  can define an angle θ 2  from a center axis defined by the center  806 . In the example of  FIG. 8A , the angles θ 1 , θ 2  are shown as being substantially 45 degrees. The angles θ 1 , θ 2  can define a bias angle or orientation of the plies  810 ,  820 . The angles θ 1 , θ 2  can be tuned in order to optimize a wall strength of the wheel component, such as being tunable to be a degree value of substantially between 22.5 and 75 degrees, such as being substantially between 40 and 60 degrees, and the like. 
     In the example of  FIG. 8A , the first ply  810  and the second ply  820  can be substantially rectangular structures. The first and second plies  810 ,  820  can overlap one another to form a cross pattern with the second edge  822  extending over and across the first edge  812 . The first and second plies  810 ,  820  together can define an arrangement or grouping of plies. In this regard, the radial pattern of plies  802  can include a plurality of the arrangement of plies  810 ,  820  to define the radial crossply. Multiple arrangements of plies can be grouped together and layered over one another to define the wall portion. For example, the wall portion can include multiple layers of crossply laminate, including a 6 layer crossply laminate, with 12, 22, or more overlapping courses of tape, according to one exemplary illustration. 
     For example, and as show in  FIG. 8B , a wall portion  850  is shown formed from the layup  800  of  FIG. 8A . For example, the radial pattern of plies  802  can be plied together and formed into a composite structure. The composite structure having the radially crossply pattern can be shaped or formed into a portion of the continuous wheel component, such as being formed into the wall portion. Sample formation techniques incudes, stamping, pressing, molding, thermal forming, and like, as described throughout.  FIG. 8B  shows the composite having the radial cross ply pattern of  FIG. 8A  formed into the wall portion  850 . In the formed shaped of the wall portion  850 , the first edge  812  and the second edge  822  can maintain the bias angles θ 1 , θ 2 , such as maintain the substantially 45 degree value, thereby enhancing wall strength of the component. As noted above, the bias angles can range from a degree value of substantially between 22.5 and 75 degrees, such as being substantially between 40 and 60 degrees, and the like. 
     Turning to  FIGS. 9A-9D , multiple other example layups of reinforced thermoplastic components are shown. The layup of  FIGS. 9A-9D  can be used to form a wall portion of the wheel component substantially analogously to the layup  800  described above with respect to  FIGS. 8A and 8B . As illustrated in  FIGS. 9A-9D , the shape, orientation, and number of plies used to form a wall portion of the wheel component can vary to provide different structural properties, geometries, and/or surface finishes. 
     With reference to  FIG. 9A , a first layup  900   a  is shown. The first layup  900   a  includes a radial pattern of plies  910   a . The radial pattern of plies  910   a  are arranged along a wall portion outline  902 . The wall portion outline  902  can define a center  906 . The radial pattern of plies  910   a  can include a ply  912   a  having a first end  914   a , a second end  916   a , and an edge  918   a . The edge  918   a  can define a bias angle θ 9a  from a center axis defined by the center  906 . In the example of  FIG. 9A , the first end  914   a  and be different than the second  916   a . For example, the first end  914   a  can be oriented substantially transverse relative to the edge  918   a , and the second end  916  can extend at an angle greater than 90 degrees from the edge  918   a . The radial pattern of plies  910   a  are disposed about the wall portion overlap so that the ends of the respective plies abut one another to define and complete a radial crossply pattern. 
     With reference to  FIG. 9B , a second layup  900   b  is shown. The second layup  900   b  includes a radial pattern of plies  910   b . The radial pattern of plies  910   b  are arranged along a wall portion outline  902 . The wall portion outline  902  can define a center  906 . The radial pattern of plies  910   b  can include a ply  912   b  having a first end  914   b , a second end  916   b , and an edge  918   b . The edge  918   b  can define a bias angle θ 9b  from a center axis defined by the center  906 . In the example of  FIG. 9B , the ply  912   b  can be rotated relative to a ply layer above or below the ply  912   b . For example, the ply  912   b  can be rotated in order to overlap an abutting connection of ply below. In this regard, the ply  192   b  can be rotated to establish a desired connection to the ply below to further tune the wall strength of the wheel component. 
     With reference to  FIG. 9C , a third layup  900   c  is shown. The third layup  900   c  includes a radial pattern of plies  910   c . The radial pattern of plies  910   c  are arranged along a wall portion outline  902 . The wall portion outline  902  can define a center  906 . The radial pattern of plies  910   c  can include a ply  912   c  having a first end  914   c , a second end  916   c , and an edge  918   c . The edge  918   c  can define a bias angle θ 9c  from a center axis defined by the center  906 . In the example of  FIG. 9 c   , the first end  914   c  can be generally similar to that of the second end  914   b . For example, the first and second ends  914   a ,  914   b  can be reflections of one another and each can extend in generally opposing directions and at an angle that is greater than 90 degrees from the edge  918   c . In this regard, the ply  912   c  can be manipulated to establish a desired connection or overlap to an adjacent ply below to further tune wall strength of the wheel component. 
     With reference to  FIG. 9D , a fourth layup  900   d  is shown. The fourth layup  900   d  includes a radial pattern of plies  910   d . The radial pattern of plies  910   d  are arranged along a wall portion outline  902 . The wall portion outline  902  can define a center  906 . The radial pattern of plies  910   d  can include a ply  912   d  having a first end  914   d , a second end  916   d , and an edge  918   d . The edge  918   d  can define a bias angle θ 9d  from a center axis defined by the center  906 . In the example of  FIG. 9D , the first end  914   d  can be different than the second  916   d . For example, the first end  914   d  can be oriented substantially transverse relative to the edge  918   d , and the second end  916   d  can extend at an angle greater than 90 degrees from the edge  918   d . The radial pattern of plies  910   d  are disposed about the wall portion overlap so that the ends of respective plies abut one another to define a complete radial crossply pattern. Further in the example of  FIG. 9D , the ply  912   d  can be rotated relative to a ply layer above or below the ply  912   d . For example, the ply  912   d  can be rotated in order to overlap an abutting connection of ply below. In this regard, the ply  192   d  can be rotated to establish a desired connection to the ply below to further tune wall strength of the wheel component. While  FIGS. 9A-9D  illustrate various ply layup strategies and configurations, any additional configurations, and/or combinations of the illustrated ply layup strategies can be used to form the reinforced thermoplastic material from a plurality of plies. 
       FIG. 10A  depicts a sample wheel component  1000  prior to thermal bonding. The wheel component  1000  can be substantially analogous to the various wheel components described herein and include: a cavity  1001 , a rim bed portion  1004 , an outer annular surface  1008 , a main structure portion  1010 , a first wall portion  10112   a , a second wall portion  12   b , and an inner annular surface, redundant explanation of which is omitted here for clarity. 
       FIG. 10A  also shows the first wall portion  1012   a  as defining an engagement feature  1013   a  and the second wall portion  1012   b  as defining an engagement feature  1013   b . The engagement features  1013   a ,  1013   b  generally overlap one another at the inner annular surface  1014 . In this regard, the engagement features  1013   a ,  1013   b  can define a reinforcement region for the wheel component  1000  along which the wheel component  1000  can be adapted to receive a series of spokes.  FIG. 10A  also shows a sacrificial material  1020 . The sacrificial material  1020  can help define a shape of the cavity  1001  during a thermal bonding process. The rim bed portion  1004 , the first wall portion  1012   a , the second wall portion  1012   b , and the sacrificial material  1020  are shown mechanically engaged with one another and generally defining a loose fitting connecting. In this configuration, the collection of such components can be associated with a tooling, where they can be subjected to heat in order to form thermal bonds among the various reinforced thermoplastic materials. 
     In this regard,  FIG. 10B  shows the wheel component  1000  associated within a tooling  1030 . Generally the wheel component  1000 , as presented in  FIG. 10A , can be arranged with a tooling compartment  1040 . The tooling  1030  can be subjected to heat in order to transition the reinforced thermoplastic materials to a partially melted or melted state, where they can be thermally bonded to one another. For example, in some cases, the tooling  1030  can be subjected to a temperature of at least 400 degrees F., of at least 450 degrees F., of at least 500 degrees F., or other temperature in order to transition the reinforced thermoplastic materials toward a partially melted or melted state, which can be based on the specific material properties of the thermoplastic. 
     The tooling  1030  operates to maintain and hold the various pieces of the wheel component  1000  relative to one another during the thermal bonding. For example, the tooling  1030  can include a first plate  1032   a , a second plate  1032   b , and a third plate  1032   c . The plates  1032   a ,  1032   b ,  1032   c  can cooperate to enclose the wheel component  1000  within the tooling  1030 . While the plates  1032   a ,  1032   b ,  1032   c  are shown as segments of circular features, it will be appreciated that the plates  1032   a ,  1032   b ,  1032   c  can be continuous circular components (as illustrated in phantom in  FIG. 10B ) that operate to enclose a segmented wheel component and/or an entire continuous circular wheel component for thermal bonding therein. The first plate  1032   a  can have a contour to engage the first wall portion  1012   a , the second plate  1032   b  can have a contour  1036  configured to engage the second wall portion  1012   b , and the third plate  1032   c  can have a contour  1038  adapted to engage the rim bed portion  1004 . 
     The sacrificial material  1020  of  FIG. 10B  helps maintain the shape of the cavity of the wheel component  1000  during the thermal bonding, as described herein.  FIGS. 10C and 11  show an example of present disclosure where the shape of an internal cavity of the wheel component is maintained during thermal bonding using pressurized fluid and without a bladder. For example, an inflation component can be used to deliver a pressurized fluid to regions of tooling that define the internal cavity of the wheel component. Subsequent to thermal bonding, the inflation component can be removed. The reinforced thermoplastic material can close in and seal itself, in some cases, and/or be adapted to be closed with other, reinforced thermoplastic components, such as a portion of the inflation component that is formed from a reinforced thermoplastic material. 
     In this regard,  FIGS. 10C and 11  shows a wheel component  1080  arranged generally within a tooling  1050 . The wheel component  1080  and the tooling  1050  can be generally analogous to those described with respect to  FIGS. 10A and 10B  and include: a rim bed portion  1084 , a first wall portion  1082   a , a second wall portion  1082   b , a first plate  1052   a , a second plate  1052   b , a third plate  1052   c , a contour  1058 , and a contour  1056 . 
     The tooling  1050  can also be adapted to provide pressurized fluid to the wheel component  1080  during thermal bonding. In this regard,  FIG. 10C  shows the tooling  1050  including an inflation component  1070 . The inflation component  1070  can include an inlet  1072  that is adapted to receive pressurized fluid, such as compressed air, from a source. The inflation component  1070  can also include a tip  1074 . The tip  1074  is insertable into the tooling compartment  1060  in order to direct pressurized air to a region substantially between the pieces of the wheel component  1080 . For example the inflation component  1070  can generally extend through the third plate  1052   c  so that the tip  1074  is advanced through the rim bed portion  1084  at an opening  1085 . The inflation component  1070  can be configured to deliver pressurized air to the tooling compartment  1060  of at least 40 psi, or of at least 100 psi, or of at least 200 psi, and/or delivery at a higher pressure, each of which can be tuned to mitigate the deformation of the reinforced thermoplastic material into the cavity. To facilitate the foregoing, the inflation component  1070  can also be associated with an adaptor  1087 . The adaptor  1087  can be associated with the tip  1074  via an O-ring  1086  or other sealing structure. As shown in  FIG. 10C , the adaptor  1087  can fit at least partially into the cavity of the wheel component  1080  to facilitate delivery of the pressurized fluid into the internal cavity and minimize leakages. Subsequent to thermally bonding the reinforced thermoplastic materials, the tooling  1050  can be allowed to cool and/or be subjected to an active cooling process. The inflation component  1070  can be removed from the wheel component  1080 , and the hole  1085  can be closed. Many mechanisms are possible and described herein. For example, the reinforced thermoplastic materials can be constructed for substantially self-sealing of the hole  1085 . This can be facilitated by a higher-melt temperature film that can be plied to a stamp form shape of the wheel components and/or a consolidated panel. In other cases, a separate plug, patch, or reinforcement strip can be used to close the hole  1085 , which can also be formed from a reinforced thermoplastic material. The materials can cool together in a manner that closes the hole  1085  in a seamless fashion, leaving substantially no visible indication of the hole  1085  in the finished product. In this regard, the rim bed portion  1084  and/or the main structure portion  1082  can be fully formed as reinforced thermoplastic components having a continuously hollow cavity and be free of surface indicia of a manufacturing process associated with bladder exit. 
     In certain other cases, the inflation component  1070  can be used to seal a hole or other point of entry for pressurized air into the cavity. For example,  FIGS. 12 and 13  present a wheel component  1200  that can have an internal cavity that is pressurized by an inflation component  1250 . The wheel component  1200  and the inflation component  1250  can be substantially analogous to the wheel component  1000  and the inflation component  1120  of  FIG. 11  and include a main structure portion  1204 , a first wall portion  1208   a , a second wall portion  1208   b  a hole  1206 , a cavity  1210 , an inlet or shaft portion  1254 , and a tip  1258 . The inflation component  1250  can deliver pressurized air into the cavity  1210  via the tip  1258 , as shown in  FIG. 13 . For example, the tip  1258  can have a duct  1262  that allows a flow of pressurized air in the cavity  1210 . 
     A portion of the inflation component  1250 , such as the tip  1262 , can be a consumable component that is used to seal the hole  1206 . For example, the tip  1262  can be formed from a thermoplastic material (which may or may not be reinforced) and/or other material that generally has a higher melting temperature than that of the reinforced thermoplastic material used to form the rim bed portion  1204  and/or the first or second wall portions  1208   a ,  1208   b . Subsequent to the thermal bonding of the portions of the wheel component  1200 , the tip  1258  can be severed from the shaft  1254 . The tip  1258  can remain partially integrated with the rim bed portion  1204  such as being integrated with the hole  1206  and used to seal and plug the hole  1206 . For example, the tip  1258  can cool according to a different thermal characteristic than the surround rim bed portion  1204 . This differential can encourage the rim bed portion  1204  to at least partially close in on itself and seal the hole  1206 , using the tip  1258  to plug or block the hole  1206 . The cavity  1210  can be therefore sealed from an external environment. The self-sealing properties of the rim bed portion  1204  in cooperation with the tip  1258  can define a substantially smooth, seamless exterior surface of the wheel component. 
     As stated above, the pieces of any of the wheel components described herein can be thermally bonded to one another to form a segment of a continuous circular shape. Additionally or alternatively, the pieces of the wheel components can be thermally bonded to one another to form the continuous circular shape.  FIG. 14  depicts a sample tooling  1400  that be used to thermally bond the pieces of the wheel component as a continuous circular shape. In this regard, it will be appreciated that the tooling described with reference to  FIGS. 9 and 10  can be, or be adapted to define, the continuous circular tooling  1400  presented in  FIG. 14 . 
     Broadly,  FIG. 14  shows the tooling  1400  as including a first plate  1408   a  and a second plate  1408   b . The tooling  1400  also includes a collection of annular members  1412 . The pieces of the wheel component are arranged generally between the plates  1408   a ,  1408   b  and the collection of annular members  1412  encircle the pieces of the wheel component. The example of  FIG. 14  shows a wheel component  1404  arranged within the tooling  1400 . The wheel component  1404  can be substantially analogous to any of the wheel components described herein and include a rim bed portion  1220  and a main structure portion  1224 , redundant explanation of which is omitted here for clarity. In some cases, the rim bed portion  1220  and the main structure  1224  can be arranged within the tooling  1400  and thermally bonded to one another within the tooling  1400 . Additionally or alternatively, the wheel component  1404  can include wheel segments  1406  that include rim and main structure portions which are thermally bonded to one another. In this regard, multiple circular segments can be arranged with the tooling  1400  in order to define a continuous circular component, internally formed and having a substantially seamless exterior. 
       FIGS. 15A-20B  depicts various examples of wheel components that are formed fully from reinforced thermoplastic materials. The wheel components of  FIGS. 15A-20B  can be formed via a thermal bonding process. For example, one or more components of a rim bed portion and a main structure portion that are each formed from a reinforced thermoplastic material can be arranged relative to one another and joined together. The rim bed portion and main structure portion can be constructed in a variety of manners to facilitate thermal bonding. For example, the rim bed portion and the main structure portion can include overlapping portions that are adapted to mechanically engage with one another in order to form a lap joint. Additionally or alternatively, the rim bed portion and the main structure portion can be adapted to form an edge joint, among other constructions. In some cases, one or both of the rim bed portion or the main structure portion can be associated with another reinforced thermoplastic material, such as a reinforced thermoplastic material that is adaptable to define a reinforced zone of the wheel component that is strengthened to receive spokes or other features of a bicycle. It will be appreciated that while  FIGS. 15A-20B  show sample constructions of wheel components, in other cases other constructions are contemplated herein. 
     With reference to  FIGS. 15A and 15B , a wheel component  1500  is shown. The wheel component  1500  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  1500  is shown in  FIGS. 15A and 15B  as including a first wall portion  1512   a  and a second wall portion  1512   b . The first wall portion  1512   a  and the second wall portion  1512   b  cooperate to enclose the wheel component  1500  and define a cavity  1506 . In the example of  FIGS. 15A and 15B , the first wall portion  1512   a  and the second wall portion  1512   b  establish the rim bed portion  1504  that defines an outer annular surface of the wheel component  1500  that is configured to engage a bicycle tire. The first wall portion  1512   a  and the second wall portion  1512   b  also establish the main structure portion  1510  that can be adapted to engage spokes of a bicycle. The first wall portion  1512   a  and the second wall portion  1512   b  are mechanically engaged at the rim bed portion  1504  and the main structure portion  1510 . For example the first wall portion  1512   a  can include an engagement feature  1520   a  and the second wall portion  1512   b  can include an engagement feature  1520   b . The engagement features  1520   a ,  1520   b  can overlap one another at the rim bed portion  1504 , forming a lap joint. Collectively, the overlap of the engagement features  1520   a ,  1520   b  can define a reinforcement region  1516   b  at the rim bed portion. Further, the first wall portion  1512   a  can include an engagement feature  1524   a  and the second wall portion  1512   b  can include an engagement feature  1524   b . The engagement features  1524   a ,  1524   b  can overlap one another at the main structure portion  1510 , forming a lap joint. Collectively, the overlap of the engagement features  1524   a ,  1524   b  can define a reinforcement region  1516   a  at the main structure portion. 
     With reference to  FIGS. 16A and 16B  a wheel component  1600  is shown. The wheel component  1600  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  1600  is shown in  FIGS. 16A and 16B  as including a first wall portion  1612   a , a second wall portion  1612   b , and a rim bed portion  1604 . The first wall portion  1612   a , the second wall portion  1612   b , and the rim bed portion  1604  cooperate to enclose the wheel component  1600  and define a cavity  1606 . In the example of  FIGS. 16A and 16B , the rim bed portion  1604  is a structural component that defines an outer annular surface of the wheel component  1600  that is configured to engage a bicycle tire. The first wall portion  1612   a  and the second wall portion  1612   b  establish the main structure portion  1610  that can be adapted to engage spokes of a bicycle. The first wall portion  1612   a  and the second wall portion  1612   b  are mechanically engaged at the main structure portion  1610 . For example, the first wall portion  1612   a  can include an engagement feature  1624   a  and the second wall portion  1612   b  can include an engagement feature  1624   b . The engagement features  1624   aa ,  1624   b  can overlap one another at the main structure portion  1610 , forming a lap joint. Collectively, the overlap of the engagement features  1624   a ,  1624   b  can define a reinforcement region  1616  at the main structure portion  1610 . Further, the first wall portion  1512   a  can include an engagement feature  1620   a  and the second wall portion  1612   b  can include an engagement feature  1620   b . The engagement features  1620   a ,  1620   b  can be used to define an edge joint with the main structure portion  1604 . For example, the main structure portion  1604  can include an engagement feature  1605   a  that is mechanically engageable with the engagement feature  1620   a  to define an edge joint. The main structure portion  1604  can further include an engagement feature  1605   b  that is mechanically engageable with the engagement feature  1620   b  to define another edge joint. 
     With reference to  FIGS. 17A and 17B  a wheel component  1700  is shown. The wheel component  1700  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  1700  is shown in  FIGS. 17A and 17B  as including a rim bed portion  1704  and a main structure portion  1712 . The rim bed portion  1704  and the main structure portion  1712  cooperate to enclose the wheel component  1700  and define a cavity  1706 . In the example of  FIGS. 17A and 17B , the rim bed portion  1704  is a structural component that defines an outer annular surface of the wheel component  1700  that is configured to engage a bicycle tire. The main structure portion  1710  can be adapted to engage spokes of a bicycle. The rim bed portion  1704  is mechanically engaged at the main structure portion  1710 . For example, the rim bed portion can include engagement features  1705   a ,  1705   b . The main structure portion  1712  can include engagement features  1720   a ,  1720   b . The engagement features  1720   a ,  1705   a  can define an edge joint between the main structure portion  1712  and the rim bed portion  1704 . Further, the engagement features  1720   b ,  1705   b  can define an edge joint between the main structure portion  1712  and the rim bed portion  1704 .  FIG. 17  further shows the wheel component as including a reinforcement region  1716  at the main structure portion  1712 , for example, as might be adapted or strengthened to receive a series of spokes. For example, the wheel component  1700  can further include a reinforcement piece  1718 , which can also be formed from a reinforced thermoplastic material. The reinforcement piece can overlap or cover or be laminated with the main structure portion  1712  to define the reinforcement region  1712 . 
     With reference to  FIGS. 18A and 18B  a wheel component  1800  is shown. The wheel component  1800  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  1800  is shown in  FIGS. 18A and 18B  as including a first wall portion  1812   a , a second wall portion  1812   b , a first rim bed portion  1804   a , and a second rim bed portion  1804   b . The first wall portion  1812   a , the second wall portion  1812   b , the first rim bed portion  1804   a , and the second rim bed portion  1804   b  cooperate to enclose the wheel component  1800  and define a cavity  1806 . In the example of  FIGS. 18A and 18B , the first rim bed portion  1804   a  and the second rim bed portion  1804   b  establish the rim bed portion  1804  of the wheel component  1800 . The rim bed portion  1804  defines an outer annular surface of the wheel component  1800  that is configured to engage a bicycle tire. Further, the first wall portion  1812   a  and the second wall portion  1812   b  establish the main structure portion  1810  that can be adapted to engage spokes of a bicycle. The first wall portion  1812   a  and the second wall portion  1812   b  are mechanically engaged at the rim bed portion  1804  and the main structure portion  1810 . For example, the first wall portion  1812   a  can include an engagement feature  1824   a  and the second wall portion  1812   b  can include an engagement feature  1824   b . The engagement features  1824   a ,  1824   b  can overlap one another at the main structure portion  1810 , forming a lap joint. Collectively, the overlap of the engagement features  1824   a ,  1824   b  can define a reinforcement region  1816   a  at the rim bed portion  1810 . Further, the first rim bed portion  1804   a  and the second rim bed portion  1804   b  can also form a reinforcement region  1816   b  at the rim bed portion  1804 . For example, the first rim bed portion  1804   a  can include an engagement feature  1818   a  and the second rim bed portion  1818   b  can include an engagement feature  1818   b . The engagement features  1818   a ,  1818   b  can overlap one another at the rim bed portion  1804 , forming a lap joint that defines the reinforcement region  1816   b . The rim bed portion  1804  is also adapted to form edge joints with the main structure portion  1810 . For example, the first wall portion  1812   a  can include an engagement feature  1820   a  and the first rim bed portion  1804   a  can include an engagement feature  1819   a . The engagement features  1820   a ,  1819   a  can be arranged relative to one another to form the edge joint. Further, the second wall portion  1812   b  can include an engagement feature  1820   b  and the second rim bed portion  1804   b  can include an engagement feature  1819   b . The engagement features  1820   b ,  1819   b  can be arranged relative to one another to form the edge joint. 
     With reference to  FIGS. 19A and 19B  a wheel component  1900  is shown. The wheel component  1900  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  1900  is shown in  FIGS. 19A and 19B  as including a first wall portion  1912   a , a second wall portion  1912   b , a rim bed portion  1904 , and a shell  1950 . The first wall portion  1912   a , the second wall portion  1912   b , the rim bed portion  1904 , and the shell  1950  cooperate to enclose the wheel component  1900  and define a cavity  1906 . In the example of  FIGS. 19A and 19B , the rim bed portion  1904  is a structural component that defines an outer annular surface of the wheel component  1700  that is configured to engage a bicycle tire. Further, the first wall portion  1912   a , the second wall portion  1912   b , and the shell  1950  establish the main structure portion  1910  that can be adapted to engage spokes of a bicycle. The first wall portion  1912   a  and the second wall portion  1912   b  are mechanically engaged at the main structure portion  1910 . For example the first wall portion  1912   a  can include an engagement feature  1924   a  and the second wall portion  1912   b  can include an engagement feature  1924   b . The engagement features  1924   a ,  1924   b  can overlap one another at the main structure portion  1910 , forming a lap joint. Collectively, the overlap of the engagement features  1924   a ,  1924   b  can define a reinforcement region  1916   a  at the rim bed portion  1910 . Further, the rim bed portion  1904  can also form reinforcement regions, such as reinforcement regions  1916   b ,  1916   c  shown in  FIGS. 19A and 19B . For example, the first wall portion  1912   a  can include an engagement feature  1920   a  that is arrangeable relative to the rim bed portion  1904  to define the reinforced region  1916   b . Further, the second wall portion  1912   b  can include an engagement feature  1920   b  that is arrangeable relative to the rim bed portion  1904  to define the reinforced region  1916   b . The reinforced regions  1916   a ,  1916   b  can be reinforced corners of the rim bed portion  1904 , which can be configured to support and/or enhance the functionality of certain bicycle tires engaged with the rim bed portion  1904 . The rim bed portion  1904  is also adapted to form edge joints with the main structure portion  1910 . For example, the shell can include an engagement feature  1952   aa  and the rim bed portion  1904  can include an engagement feature  1905   a . The engagement features  1952   a ,  1905   a  can be arranged relative to one another to form the edge joint. Further, the shell can include an engagement feature  152   bb  and the rim bed portion  1904  can include an engagement feature  1905   b . The engagement features  1952   b ,  1905   b  can be arranged relative to one another to form the edge joint. 
     With reference to  FIGS. 20A and 20B  a wheel component  2000  is shown. The wheel component  2000  can be substantially analogous to the various wheel components and the reinforced thermoplastic structures described herein; redundant explanation of which is omitted here for clarity. The wheel component  2000  is shown in  FIGS. 20A and 20B  as including a first wall portion  2012   a , a second wall portion  2012   b , a first rim bed portion  2004   a , and a second rim bed portion  2004   b . The first wall portion  2012   a , the second wall portion  2012   b , the first rim bed portion  2004   a , and the second rim bed portion  2004   b  cooperate to enclose the wheel component  2000  and define a cavity  2006 . In the example of  FIGS. 20A and 20B , the first rim bed portion  2004   a  and the second rim bed portion  2004   b  establish the rim bed portion  2004  of the wheel component  2000 . The rim bed portion  2004  defines an outer annular surface of the wheel component  2000  that is configured to engage a bicycle tire. Further, the first wall portion  2012   a  and the second wall portion  2012   b  establish the main structure portion  2010  that can be adapted to engage spokes of a bicycle. The first wall portion  2012   a  and the second wall portion  2012   b  are mechanically engaged at the rim bed portion  2004  and the main structure portion  2010 . For example, the first wall portion  2012   a  can include an engagement feature  2024   a  and the second wall portion  2012   b  can include an engagement feature  2024   b . The engagement features  2024   a ,  2024   b  can overlap one another at the main structure portion  2010 , forming a lap joint. Collectively, the overlap of the engagement features  2024   a ,  2024   b  can define a reinforcement region  2016   a  at the rim bed portion  2010 . Further, the first rim bed portion  2004   a  and the second rim bed portion  2004   b  can also form a reinforcement region  2016   b  at the rim bed portion  2004 . The rim bed portion  2004  is also adapted to form edge joints with the main structure portion  2010 . For example, the first wall portion  2012   a  can include an engagement feature  2020   a  and the first rim bed portion  2004   a  can include an engagement feature  2019   a . The engagement features  2020   a ,  2019   a  can be arranged relative to one another to form the edge joint. Further, the second wall portion  2012   b  can include an engagement feature  2020   b  and the second rim bed portion  2004   b  can include an engagement feature  2019   b . The engagement features  2020   b ,  2019   b  can be arranged relative to one another to form the edge joint. 
       FIGS. 21A-25B  depict further examples of thermal bonding of reinforced thermoplastic components. In particular,  FIGS. 21A-25B  depict multi-stage thermal bonding techniques. For example, it can be desirable in certain circumstances to complete a spoke bed bond or weld (e.g., bonding components of a main structure portion to one another), and in turn complete a channel bond or weld (e.g., bonding components of a rim bed portion to one another and/or with the main structure portion). It will be appreciated therefore, that the following techniques can be adapted to thermally bond any of the reinforced thermoplastic materials to one another, including thermal bonding to form a circular segment and/or a continuous circular component. 
     With reference to  FIGS. 21A and 21B , a first example of a multi-stage thermal bonding technique is depicted.  FIG. 21A  shows an operation  2100   a  in which a spoke bed weld or bond is performed, and  FIG. 21B  shows an operation  2100   b  in which a channel weld or bond is performed. As shown in  FIG. 21A , a main structure portion  2150  can generally be held within a tooling. The tooling can include a first half  2104   a  and a second half  2104   b . The first and second halves  2104   a ,  2104   b  can operate as outer support members that clamp the pieces of the wheel component in the tooling. A first cradle portion  2114   a  and a second cradle portion  2114   b  can contact and engage the main structure portion  2150  within the tooling. An annular member  2106  can retain the main structure portion  2150  therein, helping to hold the portion  2150  against the cradles  2114   a ,  2114   b . A cavity  2152  can be defined by the main structure portion  2150  and the annular member  2106 .  FIG. 21A  also shows conduction rings  2108   a ,  2108   b . The conduction rings  2108   a ,  2108   b  can be used to generate heat within the cradle portions  2114   a ,  2114   b  that can be used to thermally bond components of the main structure portion  2150  and/or otherwise facilitate a spoke bed weld of the wheel component. Phenolic insulating rings  2112   a ,  2112   b  can provide an electrically insulating feature that limits the flow of heat to non-target areas during the thermal bonding. With reference to  FIG. 21B , the operation  2100   b  shows the thermal bonding of a rim bed portion  2156  to the main structure portion  2150 . In the operation  2100   b , heat is generated proximate a channel of the rim bed portion  2156  via conduction rings  2132   a ,  2132   b . Phenolic insulting rings  2128   a ,  2128   b  are provided to limit the flow of heat to non-target areas during the thermal bonding. 
     With reference to  FIGS. 22A and 22B , a second example of a multi-stage thermal bonding technique is depicted.  FIG. 22A  shows an operation  2200   a  in which a spoke bed weld or bond is performed, and  FIG. 22B  shows an operation  2200   b  in which a channel weld or bond is performed. As shown in  FIG. 22A , a main structure portion  2250  can generally be held within a tooling. The tooling can include a first half  2204   a  and a second half  2204   b . The first and second halves  2204   a ,  2204   b  can operate as outer support members that clamp the pieces of the wheel component in the tooling. A first cradle portion  2214   a  and a second cradle portion  2214   b  can contact and engage the main structure portion  2250  within the tooling. An annular member  2206  can retain the main structure portion  2250  therein, helping to hold the portion  2250  against the cradles  2214   a ,  2214   b . The annular member  2206  can also extend toward and push against the main structure portion  2250  to help define contour  2253  during thermal bonding.  FIG. 22A  also shows conduction rings  2208   a ,  2208   b . The conduction rings  2208   a ,  2208   b  can be used to generate heat within the cradle portions  2214   a ,  2214   b  that can be used to thermally bond components of the main structure portion  2250  and/or otherwise facilitate a spoke bed weld of the wheel component. Phenolic insulating rings  2212   a ,  2212   b  can provide an electrically insulating feature that limits the flow of heat to non-target areas during the thermal bonding. With reference to  FIG. 22B , the operation  2200   b  shows the thermal bonding of a rim bed portion  2256  to the main structure portion  2250 . A cavity  2252  can be defined by the main structure portion  2250  and the rim bed portion  2256 . In the operation  2200   b , heat is generated proximate a channel of the rim bed portion  2256  via conduction rings  2232   a ,  2232   b . Phenolic insulting rings  2228   a ,  2228   b  are provided to limit the flow of heat to non-target areas during the thermal bonding. 
     With reference to  FIGS. 23A and 23B , a third example of a multi-stage thermal bonding technique is depicted.  FIG. 23A  shows an operation  2300   a  in which a spoke bed weld or bond is performed, and  FIG. 23B  shows an operation  2300   b  in which a channel weld or bond is performed. As shown in  FIG. 23A , a main structure portion  2350  can generally be held within a tooling. The tooling can include a first cradle portion  2314   a , a second cradle portion  2314   b , a third cradle portion  2314   c , and a fourth cradle portion  2014   d , each of which cooperate to contact and engage the main structure portion  2350  within the tooling. A cavity  2352  can be defined by the main structure portion  2350  and the third and fourth cradles  2314   c ,  2314   d .  FIG. 23A  also shows conduction rings  2308   a ,  2308   b . The conduction rings  2308   a ,  2308   b  can be used to generate heat with the cradle portions  2314   a ,  2314   b  that can be used to thermally bond components of the main structure portion  2350  and/or otherwise facilitate a spoke bed weld of the wheel component. Phenolic insulating rings  2312   a ,  2312   b  can provide an electrically insulating feature that limits the flow of heat to non-target areas during the thermal bonding. With reference to  FIG. 23B , the operation  2300   b  shows the thermal bonding of a rim bed portion  2356  to the main structure portion  2350 . In the operation  2300   b , heat is generated proximate a channel of the rim bed portion  2356  via conduction rings  2332   a ,  2332   b . Phenolic insulting rings  2328   a ,  2328   b  are provided to limit the flow of heat to non-target areas during the thermal bonding. 
     With reference to  FIGS. 24A and 24B , a fourth example of a multi-stage thermal bonding technique is depicted.  FIG. 24A  shows an operation  2400   a  in which a spoke bed weld or bond is performed, and  FIG. 24B  shows an operation  2400   b  in which a channel weld or bond is performed. As shown in  FIG. 24A , a main structure portion  2450  can generally be held within a tooling. The tooling can include a first cradle portion  2414   a  and a second cradle portion  2414   b , each of which cooperate to contact and engage the main structure portion  2450  within the tooling. A cavity  2452  can be defined by the main structure portion  2450  and the cradles  2414   a ,  2414   b .  FIG. 24A  also shows conduction rings  2408   a ,  2408   b . The conduction rings  2408   a ,  2408   b  can be used to generate heat with the cradle portions  2414   a ,  2414   b  that can be used to thermally bond components of the main structure portion  2450  and/or otherwise facilitate a spoke bed weld of the wheel component. Phenolic insulating rings  2412   a ,  2412   b  can provide an electrically insulating feature that limits the flow of heat to non-target areas during the thermal bonding. With reference to  FIG. 24B  the operation  2400   b  shows the thermal bonding of a rim bed portion  2456  to the main structure portion  2450 . In the operation  2400   b , heat is generated proximate a channel of the rim bed portion  2456  via conduction rings  2432   a ,  2432   b . Phenolic insulting rings  2428   a ,  2428   b  are provided to limit the flow of heat to non-target areas during the thermal bonding. 
     With reference to  FIGS. 25A and 25B , a fifth example of a multi-stage thermal bonding technique is depicted.  FIG. 25A  shows an operation  2500   a  in which a spoke bed weld or bond is performed, and  FIG. 25B  shows an operation  2500   b  in which a channel weld or bond is performed. As shown in  FIG. 25A , a main structure portion  2550  can generally be held within a tooling. The tooling can include a first half  2504   a  and a second half  2504   b . The first and second halves  2504   a ,  2504   b  can operate as outer support members that clamp the pieces of the wheel component in the tooling. A first cradle portion  2514   a  and a second cradle portion  2514   b  can contact and engage the main structure portion  2550  within the tooling. An annular member  2506  can retain the main structure portion  2550  therein, helping to hold the portion  2550  against the cradles  2514   a ,  2514   b . A cavity  2552  can be defined by the main structure portion  2550  and the annular member  2506 .  FIG. 25A  also shows conduction rings  2508   a ,  2508   b . The conduction rings  2508   a ,  2508   b  can be used to generate heat with the cradle portions  2514   a ,  2514   b  that can be used to thermally bond components of the main structure portion  2550  and/or otherwise facilitate a spoke bed weld of the wheel component. Phenolic insulating rings  2512   a ,  2512   b  can provide an electrically insulating feature that limits the flow of heat to non-target areas during the thermal bonding. With reference to  FIG. 25B , the operation  2500   b  shows the thermal bonding of a rim bed portion  2556  to the main structure portion  2550 . In the operation  2500   b , heat is generated proximate a channel of the rim bed portion  2556  via conduction rings  2532   a ,  2532   b . Phenolic insulting rings  2528   a ,  2528   b  are provided to limit the flow of heat to non-target areas during the thermal bonding.  FIG. 25B  also shows another annular member  2507  that is used to hold the rim bed portion  2556  adjacent the main structure portion  2550 . The another annular member  2507  can be adapted to define a contoured surface that matches and/or is used to form a matching contour of the rim bed portion  2556 , such as that used to engage a bicycle tire. 
     Turning to  FIG. 26 , a wheel component  2600  is shown. The systems and techniques of the present disclosure can be used to produce a wide variety of shapes and components from reinforced thermoplastic material. This can include shapes and components having curved contours and/or substantially hollow interiors, such as the various wheel components and assemblies described herein. The systems and techniques can also be used to produce another wheel designs, such as the wheel component  2600  which can substantially define a tri-spoke shape. 
     For example, the wheel component  2600  can have a rim  2604  with a substantially circular contour that defines an outer perimeter of the wheel component  2600 . The rim  2604  can be smooth and substantially seamless, according to the various methods described herein. The wheel component can also include a series of spokes  2608 . The spokes  2608  can be integrally formed with the rim  2604  and associated therewith at one or more curved regions  2620 . While the series of spokes  2608  includes five spokes in  FIG. 26 , it will be appreciated that the series of spokes  2608  more generally cooperate to define the tri-spoke design of the wheel component  2600 . In this regard, the series of spokes  2608  can include three spokes, integrally formed with the rim  2604 . The wheel component  2600  can also include a hub  2624 . The hub  2624  can be integrally formed with some or all of the series of spokes  2608  and associated therewith at one or more curved regions  2624 . The hub can define an opening  2616  that is adapted to receive a component of a bicycle. 
     The wheel component  2600  can be formed fully from a reinforced thermoplastic material. In this regard, each of the rim  2604 , the series of spokes  2608 , and the hub  2612  can be formed from a reinforced thermoplastic material. The rim  2604 , the series of spokes  2608 , and the hub  2612  can be bonded to one via any of the thermal bonding processes described herein. In some cases, one or more of the rim  2604 , the series of spokes  2608 , and the hub  2612  can be formed as a substantially hollow component. 
     It is contemplated and described herein that the systems and techniques for forming a component from reinforced thermoplastic materials can be used to construct a wide variety of applications where a sufficiently high strength-to-weight ratio is desired. For example, the systems and techniques described herein can be adapted to produce components that have a sealed, hollow interior and/or define a complex, seamless exterior contour. As one illustration,  FIGS. 27A-27B  depict the application of systems and techniques described herein to wind turbines, and wind turbine blades. It will be appreciated, however, that the example of  FIGS. 27A-27B  is meant as an illustration of other non-wheel applications of the systems and techniques described herein rather than be limiting. 
     With reference to  FIG. 27A , a wind turbine  2700  is shown. The wind turbine  2700  can include blades  2704  that are associated with a rotatable structure  2708 . The wind turbine  2700  can further include a device  2712  that is connected to the rotatable structure  2708  and is configured for energy transfer upon the rotation of the rotatable structure  2708 . The blade  2704  can be sufficiently strong to withstand the force of wind and gravitational forces, but light in order to rotate. The blades  2704  can be formed full from a reinforced thermoplastic material, according to one or more the techniques described herein. 
     For example, with reference to  FIG. 27B , a cross-sectional view of the blade  2704  is depicted, taken along line  27 B- 27 B of  FIG. 27A . The blade  2704  can have an external contour  2750  that is substantially smooth and seamless, according to the techniques described herein. The blade  2704  can further include a cavity  2752 . The cavity  2752  can be substantially sealed from an external environment. The blade  2704  can be formed to meet target aerodynamic specifications, and as such defining a leading edge  2756  and a trailing edge  2758 . One or both of the leading edge  2756  or the trailing edge  2758  can be curved or partially curved. Further, one or both of the leading edge  2765  or the trailing edge  2758  can define a sharp edge of the blade  2704 . The reinforced thermoplastic material can be tuned to have a thickness  2754 . 
     To facilitate the reader&#39;s understanding of the various functionalities of the examples discussed herein, reference is now made to the flow diagram in  FIGS. 28, 29, 30, and 31 , which illustrates processes  2800 ,  2900 ,  3000 , and  3100 , respectively. While specific steps (and orders of steps) of the methods presented herein have been illustrated and will be discussed, other methods (including more, fewer, or different steps than those illustrated) consistent with the teachings presented herein are also envisioned and encompassed with the present disclosure. 
     In this regard, with reference to  FIG. 28 , process  2800  relates generally to a method of manufacturing a fully reinforced thermoplastic wheel component. The process  2800  can be used with any of the wheel components and tooling described herein, for example, such as the wheel components  300 ,  400 ,  500 ,  600 ,  800 ,  1000 ; and the tooling  900 ,  1050 ,  1200 ; and variations and combinations thereof. 
     At operation  2804 , a rim bed portion and a main structure portion can be arranged within a tooling compartment. The rim bed portion and the main structure portion can be formed from a reinforced thermoplastic material. For example and with reference to  FIGS. 10A and 10B , the rim bed portion  1004  and the main structure portion  1010  can be arranged in the tooling compartment  1040 . The rim bed portion  1004  and the main structure portion  1010  can be formed from a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, redundant explanation of which is omitted here for clarity. 
     At operation  2808 , a region of compartment that is between the rim bed portion and the main structure portion can be pressurized. For example and with reference to  FIG. 10C , the tooling compartment  1060  can be pressurized. The inflation component  1070  can deliver a compressed air to a region of the tooling  1050  that is substantially between the rim bed portion  1084  and the main structure portion  1080  to maintain a shape of a cavity of the wheel component during thermal bonding. 
     At operation  2812 , the rim bed portion and the main structure portion can be bonded by heating the reinforced thermoplastic material above a melting temperature. For example and with reference to  FIG. 11 , the rim bed portion  1084  and the first wall portion  1082   a  and second wall portion  1082   b  can be thermally bonded to one another. For example, the tooling  1050  can be subjected to heat, such as heat that is an excess of 450 degrees, that causes one or more of the main structure portion  1084 , the first wall portion  1082   a , and/or the second wall portion  1082   b  to transition toward or into a partially melted or melted state. 
     At operation  2816 , a cavity can be defined by the rim bed and the main structure portion and the cavity can be sealed. For example and with reference to  FIG. 11 , the cavity of the wheel component  1050  can be sealed. Subsequent to thermal bonding of the pieces of the wheel component  1110 , the inflation component  1170  can be removed from the cavity. In some cases, the opening  1085  can be allowed to close with exit of the inflation component  1170 . For example, the reinforced thermoplastic material of the rim bed portion  1004  can be largely self-sealing. Additionally or alternatively, a higher-temp film, plug or other structure can cooperate to seal the opening  1085 . 
     In this regard, with reference to  FIG. 29 , process  2900  relates generally to a method of manufacturing a fully reinforced thermoplastic wheel component. The process  2900  can be used with any of the wheel components and tooling described herein, for example, such as the wheel components  300 ,  400 ,  500 ,  600 ,  800 ,  1000 ; and the tooling  900 ,  1050 ,  1200 ; and variations and combinations thereof. 
     At operation  2904 , a rim bed portion can be formed from a first reinforced thermoplastic material. For example and with reference to  FIG. 7A , the rim bed portion  708  can be formed from a first thermoplastic material. A stamping operation can manipulate the first thermoplastic material into the shape of the rim bed portion  708 . 
     At operation  2908 , a main structure portion can be formed from a second reinforced thermoplastic material. For example and with reference to  FIGS. 7B and 7C , the wall portions  718 ,  728  can be formed from a second thermoplastic material. A stamping operation can manipulate the second thermoplastic material into the shape of the wall portions  718 ,  728 . 
     At operation  2912 , the fully reinforced thermoplastic wheel component can be formed as a continuous circular component. The operation of forming can occur by thermally bonding the rim bed portion and the main structure portion to one another within a tooling compartment. For example and with reference to  FIG. 14 , the rim bed portion  1220  and the main structure portion  1224  can be mechanically engaged with one another. The rim bed portion  1220  and the main structure portion  1224  can be mechanically engaged with one another and arranged within a tooling  1200 , which can define a continuous circular shape therein. The tooling  1200  can be subjected to heat, allowing the rim bed portion  1220  and the main structure portion  1224  to thermally bond to one another therein. The rim bed portion  1220  and the main structure portion  1224  can be removed from the tooling  1200  as an integrally formed structure having a continuous, substantially seamless exterior contour. 
     In this regard, with reference to  FIG. 30 , process  3000  relates generally to a method of manufacturing a fully reinforced thermoplastic wheel component. The process  3000  can be used with any of the wheel components and tooling described herein, for example, such as the wheel components  300 ,  400 ,  500 ,  600 ,  800 ,  1000 ; and the tooling  900 ,  1050 ,  1200 ; and variations and combinations thereof. 
     At operation  3004 , a film can be plied to a reinforced thermoplastic material. The film can have a higher melting temperature than that of the reinforced thermoplastic material. For example and with reference to  FIG. 7D , the film  754  can be plied to a stamp form shape  762 . The film  754  can have a higher melting temperature than that of the stamp form shape  762 , which is formed from a reinforced thermoplastic material. Further, as shown in  FIG. 7E , the film  784  can be plied to the consolidated panel  792 . The film  784  can have a higher melting temperature than that of the consolidated panel  792 . 
     At operation  3008 , a cavity can be defined with the reinforced thermoplastic material and the plied film. For example and with reference to  FIGS. 8 and 9 , the cavity  801  can be defined using the collection of the rim bed portion  804  and the main structure portion  810 , all of which can be formed from a reinforced thermoplastic material having a plied higher-melt temperature film. 
     At operation  3012 , the cavity can be sealed using the film. For example and with reference to  FIG. 11 , the rim bed portion  1004  can include the higher-melt temperature film described herein. In this regard, the reinforced thermoplastic material of the rim bed  1004  and the film cool according to a different thermal characteristic. The different thermal characteristic can allow the rim bed portion  1004  to be substantially self-sealing, closing the hole  1005  upon cooling. 
     In this regard, with reference to  FIG. 31 , process  3100  relates generally to a method of manufacturing a fully reinforced thermoplastic wheel component. The process  3000  can be used with any of the wheel components and tooling described herein, for example, such as the wheel components  300 ,  400 ,  500 ,  600 ,  800 ,  1000 ; and the tooling  900 ,  1050 ,  1200 ; and variations and combinations thereof. 
     At operation  3104 , a rim bed portion and a main structure portion can be arranged to define a cavity of the fully reinforced thermoplastic wheel component. For example and with reference to  FIGS. 12 and 13 , the rim bed portion  1204  and the walls  1208   a ,  1208   b  can be arranged to define the cavity  1210 . The rim bed portion  1204  and the walls  1208   a ,  1208   b  can be arranged to define the cavity  1210  within a tooling that is adapted to form a thermal bond between the pieces held therein. 
     At operation  3108 , the cavity can be pressurized by at least partially inserting an inflation component into the cavity. The inflation component can at least partially be formed from a material having a melting temperature that is greater than a melting temperature of materials used to form the rim bed portion and the main structure portion. For example and with reference to  FIGS. 12 and 13 , the cavity  1210  can be pressurized by at least partially inserting an inflation component  1250  into the cavity  1210 . In particular, the tip  1258  can be inserted through an opening  1206  and used to direct compressed air into the cavity  1201  in order to maintain a shape of the cavity  1210  during a thermal bonding process. The tip  1258  can be at least partially formed from a material having a melting temperature that is greater than a melting temperature of the rim bed portion  1204 . 
     At operation  3112 , the cavity can be sealed using the inflation component. For example and with reference to  FIGS. 12 and 13 , the tip  1258  can be separated from a remainder of the inflation component  1250 , such as separating the tip  1258  from the shaft portion  1254 . The tip  1258  can remain at least partially engaged within the hole  1206 , defining a plug or partial plug for the flow of air therethrough. Additionally, the tip  1262  can cool according to a different thermal characteristic than that of the reinforced thermoplastic material of the rim bed portion  1204 . The different thermal characteristic can allow the rim bed portion  1204  to be substantially self-sealing, closing the hole  1005  upon cooling with the tip  1262 . 
     With reference to  FIG. 32 , process  3200  relates generally to a method of manufacturing a wall portion of a fully reinforced thermoplastic wheel component. The process  3200  can be used with any of the wheel components and tooling described herein, for example, such as the wheel components  300 ,  400 ,  500 ,  600 ,  800 ,  1000 ; and the tooling  900 ,  1050 ,  1200 ; and variations and combinations thereof. 
     At operation  3204 , a first ply of reinforced thermoplastic material is provided. For example, and with reference to  FIG. 8A , the first ply  810  is provided. The first ply  810  can include or be formed from a reinforced thermoplastic material, such as any of the materials described herein. The first ply  810  can have a first edge  812 . The first ply  810  can be provided relative to the wall portion outline  804 . For example, the first ply  810  can be arranged relative to the wall portion outline  804  to define an angle θ 1  from a center axis of the circular outline, as defined by the center  806 . 
     At operation  3208 , a second ply of reinforced thermoplastic material is provided. For example, and with reference to  FIG. 8B , the second ply  820  is provided. The second ply  820  can include or can be formed from a reinforced thermoplastic material, such as any of the materials described herein. The second ply  820  can have a second edge  822 . The second ply  820  can be provided relative to the wall portion outline  804 . For example, the second ply  820  can be arranged relative to the wall portion outline  804  to define an angle θ 2  from a center axis of the circular outline, as defined by the center  806 . 
     At operation  3212 , the first ply and the second ply are overlapped within one another in order to define an arrangement of plies. For example, and with reference to  FIGS. 8A and 8B , the first ply  810  and the second ply  820  are overlapped with one another to define an arrangement of plies of the radial pattern  802 . In one example, the first and second plies  810 ,  820  are overlapped with one another such that the first edge  812  and the second edge  822  are substantially transverse to one another. It will be appreciated, however, that the orientation of the first and second edges  812 ,  822  can be specifically chosen and/or designed with any appropriate orientation to facilitate wall strength of the wheel component. 
     At operation  3216 , a plurality of the arrangement of plies are provided to define a radial pattern of a wheel component of a wall portion. For example, and with reference to  FIGS. 8A and 8B , multiple groupings or arrangements of the plies  810 ,  820  can be provided and arranged radially along the outline  804 . The radial arrangement of the plies  810 ,  802  can define the radial cross pattern  802 , such as that shown with reference to  FIG. 8A . The layup  800  including the crossply pattern  802  can be subsequently shaped to form the wall portion  850 , according to any of the shaping techniques described herein. 
     Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, features implementing functions can also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations. Also, as used herein, including in the claims, “or” as used in a list of items prefaced by “at least one of” indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., A and Band C). Further, the term “exemplary” does not mean that the described example is preferred or better than other examples. 
     The foregoing description, for purposes of explanation, uses specific nomenclature to provide a thorough understanding of the described examples. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described examples. Thus, the foregoing descriptions of the specific examples described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the examples to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.