Development of a novel consolidation process for continuous-fiber-reinforced thermoplastics

Consolidation is an essential process step in thermoplastic tape laying. In the present study it has been shown that an inert atmosphere like nitrogen or a vacuum reduces degradation of the material during this process. Based on these findings a novel consolidation approach was developed, in which a vacuum is used to apply pressure to the laminate while infrared radiation heats the thermoplastic material through a transparent mold wall. Beside radiation power, the thickness of the mold wall is a major influencing factor on the cycle time. For thin mold walls, cycle times below one minute for the whole consolidation step can be achieved.