Carbon Fiber Reinforced Thermoplastics: From Materials to Manufacturing and Applications

Abstract Carbon fiber reinforced thermoplastics (CFRTs) have witnessed a resurgence in recent times since their first industrial use over five decades ago, with revitalized interest from aerospace companies and other key sectors including energy and automotive sectors. CFRTs are increasingly gaining footholds in high volume rapid manufacturing in aerospace and nonaerospace sectors owing to their inherent recyclability. However, there has been a lack of contemporary and critical review on this topic so far. This work aims to review the recent advances in CFRTs with emphasis on high performance thermoplastics. Both continuous and discontinuous fiber forms in tape, organosheet and short/long fiber architectures are discussed, their processing and postprocessing methods are reviewed, with emphasis on state‐of‐the‐art welding techniques. Typical applications of CFRTs in industry are examined, including fuselage, pressure vessel, and automotive components. Finally, insights are provided into ongoing challenges, future development, and a roadmap for expediting the development of high‐performance CFRTs.