ABSTRACT
This chapter discusses the shape-forming processes for continuous fiber-reinforced thermoplastic matrix composites. It describes three different shape-forming processes that are used in making thermoplastic matrix composite parts. They are: melting the thermoplastic polymer in the prepreg, shape forming and consolidation under the application of pressure, and cooling to room temperature. The consolidation of thermoplastic matrix composites starts with heating a stack of prepreg layers to the melt temperature either in the mold or outside the mold. The melt temperature is selected such that the thermoplastic transforms into a low-viscosity liquid and is able to flow under the consolidation pressure. Shape forming starts with a flat sheet of material, called the blank, that can be either an unconsolidated or a preconsolidated stack of prepregs. Voids in thermoplastic matrix composites are formed during prepregging and consolidation. Voids can occur from crystallization shrinkage during cooling, particularly if the forming pressure is released before the crystallization is complete.
