Thermoforming carbon fibre-reinforced thermoplastic composites

TLDR

Carbon fibre composites are increasingly used across industries, yet their high energy and cost inputs are mainly justified in high‑value sectors such as aerospace, where life‑cycle benefits offset the costs; thermoplastic composites differ in energy and recyclability profiles, which remain poorly quantified. The study aims to determine an optimal processing window for thermoplastic carbon fibre composites by evaluating key process control parameters and their impact on part properties. The authors analyze parameter interactions and sensitivities derived from experimental results to identify the optimal processing window. The analysis reveals how parameter interactions influence part characteristics, enabling the identification of an optimal processing window.

Abstract

The use of carbon fibre composites is growing in many sectors but their use remains stronger in very high value industries such as aerospace where the demands of the application more easily justify the high energy input needed and the corresponding costs incurred. This energy and cost input is returned through gains over the whole life of the product, with for example, longer maintenance intervals for an aircraft and lower fuel burn. Thermoplastic composites however have a different energy and cost profile compared to traditional thermosets with notable differences in recyclability, but this profile is not well quantified or documented. This study considers the key process control parameters and identifies an optimal window for processing, along with the effect this has on the final characteristics of the manufactured parts. Interactions between parameters and corresponding sensitivities are extracted from the results.