Process modelling of In-situ consolidated thermoplastic composite by automated fibre placement – A review

Thermoplastic composites boast several advantages over thermoset composites including outstanding mechanical performance, thermoformability and recyclability. Coupled with automated fibre placement and out-of-autoclave in-situ consolidation, this has driven increased interest in thermoplastic composite materials. In-situ consolidation refers to heating and consolidating the thermoplastic towpregs as they are being laid. This leverages automation to reduce the process steps, costs, and turnaround. However, in-situ consolidated thermoplastic composites by automated fibre placement have not gained wider acceptance within the industry due to ongoing concerns regarding manufacturing induced defects such as voids, poor interlaminar bonding and dimensional stability. A powerful tool available to researchers and engineers to better understand the development of such defects is process modelling. Process modelling is the analytical or numerical simulation of the in-situ consolidation process which typically involves complex interactions between the mechanical, thermal, and physical phenomena. This review paper covers the modelling approaches and material models which researchers have employed to simulate and predict the in-situ consolidation process. Experimental work on optimising the process parameters is also briefly discussed. The current limitations and future directions of process modelling for in-situ consolidation are also discussed.