Avanced Manufacturing of High-Performance Thermoplasitc Composites

Thermoplastic composites (TPCs) combine weldability, outstanding toughness, and the potential for rapid out-of-autoclave (OoA) processing—attributes that make them prime candidates for next-generation aerospace, automotive, and energy applications. In rapid-cycle processes such as additive manufacturing (AM), in-situ consolidated automated fiber placement (AFP), and welding, TPCs are exposed to extreme thermal and mechanical conditions. These environments profoundly influence their microstructure, directly impacting interlaminar bond formation and, consequently, overall structural performance. In this talk, I will present the underlying physics of interlaminar bond development in fiber–reinforced TPCs, focusing on how processing parameters and microstructural changes govern mechanical properties across multiple scales. Through case studies involving AM and in-situ consolidated AFP, I will illustrate the interplay between polymer morphology, fiber architecture, and defect management, showing how engineered voids or strategically placed defects can enable post-processing consolidation to boost performance. Additionally, I will introduce novel interfacial materials designed to facilitate more effective in-situ consolidation under rapid-cycle conditions, thereby reducing cycle times while improving part quality. By highlighting both fundamental mechanisms and practical manufacturing considerations, this talk aims to provide actionable insights into the design and processing of TPCs for high-efficiency, high-performance applications in a rapidly evolving industrial landscape.