A thermal processing and consolidation system is provided that includes an upper chamber assembly lower chamber assembly, layup and demolding station, transfer assembly, automatic or permanent coupling system, and controller. The upper and lower chamber assemblies are coupled to form an enclosed plenum operable to maintain a pressurized environment about a tool. The layup and demolding station receives the tool and facilitates the layup, bagging and sealing of unprocessed components at the tool. A transfer assembly accurately positions the tool on the lower chamber assembly in alignment with the upper chamber assembly. An automatic or permanent coupling system provides services to the tool and the enclosed plenum. A controller directs services to be supplied to the enclosed plenum and tool in accordance with a set of process parameters. This set of process parameters allows an individual set of unprocessed components to be thermally processed and consolidated.