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Fundamentals of Thermoplastic Composites
2026-09-03 15:29:48
Click：
“
Toray Advanced Composites (TAC) Thermoplastic Composites
”
THERMOPLASTIC COMPOSITES CONFERENCE
TCC 2020
A VIRTUAL EVENT
APRIL 29 ‑ MAY 1, 2020
Fundamentals of Thermoplastic Composites
Presented By: Daniel Leeser
Technology Manager, Thermoplastics
Toray Advanced Composites
PRESENTED BY ACMA Composites
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Toray — Thermoplastic Composite Matrix Supplier
Toray International
- Carbon fiber manufacturing
- Global leader in composite materials
Toray Advanced Composites (TAC)
- Thermoset prepregs & supporting materials
- Thermoplastic prepregs & supporting materials
- Compression‑molded components
Thermoplastic Composites
Unidirectional Tapes
- PEEK (Polyetheretherketone)
- PPS (Polyphenylene Sulfide)
- PEKK (Polyetherketoneketone)
- PEI (Polyetherimide)
- LMPAEK (Low‑Melting Polyaryletherketone)
- Nylon
Fabric‑Based Prepregs
- PEEK
- PPS
- PEKK
- PEI
- Nylon
- Polypropylene
- Polyethylene
- PET (Polyethylene Terephthalate)
- LMPAEK
- Polycarbonate
'TORAY'
Toray Advanced Composites
Why Thermoplastics?
Thermoplastic Advantages
Material Properties
- High fracture toughness & high CAI (Compression‑After‑Impact)
- Excellent mechanical performance
- Recyclability
- Low flame, smoke & toxicity characteristics
- Room‑temperature storage capability
- Reprocessability
Low‑Cost Manufacturing
- High‑speed part production
• Thermoforming
• Compression molding
• Continuous Compression Molding (CCM)
• Advanced Automated Fiber Placement (AFP)
- Fast part joining
• Welding
• Integrated structural design
PRESENTED BY ACMA Composites
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Large‑Scale Adoption of Thermoplastic Composites
Toward cost‑effective, weight‑optimized structures
Adoption of thermoplastic composites for commercial aerospace is accelerating
Adoption‑phase timeline:
1. TP Concept Validation Phase
Validate TP technology on secondary‑structure components
2. Thermoset Replacement & Production‑Rate Growth
Convert existing wide‑body‑aircraft thermoset parts to TP components, drive higher production rates
3. Primary Structures for Next‑Generation Aircraft
Next‑generation composite‑rich aircraft designs incorporate large amounts of TP materials
4. Broader TP Adoption
Wider‑spread implementation of thermoplastic composites
Application scopes: Fuselage, engine pylon, torque box, empennage, small‑aircraft wing
8ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace Thermoplastic‑Composite Parts
Current Applications
- Brackets & clips
- Aerial‑film components
- Leading‑edge structures
- Vertical stabilizers
- Window frames
- Overhead‑bin latch covers
- Aircraft seats
- Wing ribs
- Wingtips
- Environmental control‑system components
Future Target Applications
- Fuselage
- Wing skins
- Floor beams
- Radomes
PRESENTED BY ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace‑Part Manufacturing Processes
Primary Processes
- Automated Fiber Placement (AFP)
- Automated Tape Laying (ATL)
- Continuous Compression Molding
- Press forming
- Autoclave curing
- Vacuum forming
- Thermoforming / Stamping
- Vacuum‑Bag‑Only (VBO)
Secondary Processes
- Injection over‑molding
- Bonding
- Welding
- Painting
Machine photo labels:
Core
Infrared oven
Cavity
Blank
Shuttle Frame / holder
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Material Properties
Key material‑performance considerations
- Polymer selection
- Processing temperature
- Mechanical properties
- Solvent resistance
- Crystallization kinetics
- Polymer viscosity
- Toughness‑versus‑flow trade‑offs
• TC1225 (LMPAEK): Low melt viscosity with excellent toughness
- Prepreg quality
• Good fiber‑matrix distribution
• Consistent thickness across wide formats
• Low void content
Micrograph: Toray TC1225 / T700 prepreg
Good fiber‑matrix distribution, void‑free
Thinking question:
Why is T700 carbon fiber used for LMPAEK‑matrix composites, instead of higher‑strength T800 or T1100 fibers?
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Automated Fiber Placement (AFP)?
- Automated process for laying prepreg onto tooling with defined fiber orientation and ply lay‑up
Thermoplastic AFP
- In‑situ consolidation
Parts are fully consolidated upon removal from the tool
- Partial consolidation
Secondary consolidation process is required to eliminate part voids
- Suitable for complex parts, parts with ply drop‑off regions
- Heat sources: Hot‑gas torch, laser, UV / infrared lamps
Case reference: TAPAS 2 Pylon, May 2016
Video courtesy of NLR. Recorded for the TAPAS‑2 pylon project, 2016.
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on AFP Processing
TC1320 (PEKK)
- Difficult to produce void‑free laminates using AFP alone
- Good‑quality laminates achieved after subsequent VBO cure
AFP: High void content → After VBO: Void‑free good laminate
TC1225 (LMPAEK)
- High‑quality panels achievable with AFP only
- Root cause: Lower polymer melt viscosity of TC1225
AFP only: Void‑free → After VBO: Excellent‑quality laminate
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Laying TC1225 PAEK Tape
Material: Toray TC1225(LMPAEK)/T700GC
Evaluation of multiple lay‑down speeds
- 4 in/sec (100 mm/s)
- 8 in/sec (200 mm/s)
- 16 in/sec (400 mm/s)
Results:
Good composite quality at lay speeds up to 400 mm/s.
Robot dynamics and laser‑power limit further speed increases.
Some voids develop within the final ply at 400 mm/s.
Tool‑temperature study (fixed lay‑speed:16 in/sec = 400 mm/s)
- Room‑temperature tool
Low crystallinity, excellent consolidation
- 210 °F (100 °C) tool
Increased crystallinity, excellent consolidation
- 390 °F (200 °C) tool
Full crystallinity, deconsolidation‑induced porosity
- Room‑temperature tool + post‑anneal
Full crystallinity, excellent consolidation
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Mitigating Final‑Ply Porosity
Toray TC1225(LMPAEK)/T700GC, lay‑speed 16 in/sec (400 mm/s)
- Outer ply develops porosity
- Second compaction roller pass over the final ply eliminates porosity
Conclusion:
Compaction rollers can effectively consolidate multi‑ply stacks.
Image captions:
Outer ply — single roller pass
Outer ply — after second roller pass
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Vacuum‑Bag‑Only (VBO)?
- Out‑of‑autoclave processing solution
- Consolidate laminates using vacuum pressure plus applied heat
Advantages
- No high‑capital‑cost autoclave required; oven‑only solution typical
- Single‑sided tooling is sufficient
- Part size limited by oven / heating‑system footprint
Disadvantages
- Relatively long cure cycles
- Consumable‑material costs
Typical VBO bag‑assembly sequence
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Post‑lay‑down Oven Consolidation via VBO
Toray TC1225(LMPAEK)/T700GC
VBO / oven consolidation after tape laying
- In‑situ consolidation is not practical for certain complex geometries and ply‑drop‑off parts
- VBO / oven consolidation is a viable alternative
Relieves residual stress; increases crystallinity
Mechanical‑property performance comparable to autoclave‑ or press‑consolidated parts
Chart label: Original consolidation cycle
Micrograph caption: Void‑free
C‑scan image label: C‑scan
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on VBO Processing
VBO study on TC1225(LMPAEK)
Study objectives:
- Thick‑section laminates
Successfully processed 72‑ply (3/8 in / 10 mm) panels, 12 in × 12 in (300 mm × 300 mm)
- Short‑cycle cure development
Max temperature 625 °F (330 °C)
Heat‑up rate 9 °F/min (5 °C/min)
Cool‑down rate 5 °F/min (3 °C/min)
No isothermal hold step
Total cycle time: 3 hours
- Reduced consumable‑material usage
Study results:
Excellent laminate quality.
Micrographs confirm zero voids within laminate. (Dark features represent 90°‑oriented fibers, not voids.)
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Conclusions
Thermoplastic‑composite adoption
- Deployed across multiple aerospace‑platform applications
- Further adoption expected in future programs
- Expanding set of available manufacturing processes
- Continuous improvements in composite‑material performance
- Growing industrial‑supporting infrastructure
- Expanding toolkit for component and assembly manufacturing
Dan Leeser
Technology Manager, Thermoplastics
'TORAY'
Toray Advanced Composites
Original paper title: Advances in Understanding the Properties of Thermoplastic Composites
Compiled: Yang Chaofan, Aug 10, 2026
THERMOPLASTIC COMPOSITES CONFERENCE
TCC 2020
A VIRTUAL EVENT
APRIL 29 ‑ MAY 1, 2020
Fundamentals of Thermoplastic Composites
Presented By: Daniel Leeser
Technology Manager, Thermoplastics
Toray Advanced Composites
PRESENTED BY ACMA Composites
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Toray — Thermoplastic Composite Matrix Supplier
Toray International
- Carbon fiber manufacturing
- Global leader in composite materials
Toray Advanced Composites (TAC)
- Thermoset prepregs & supporting materials
- Thermoplastic prepregs & supporting materials
- Compression‑molded components
Thermoplastic Composites
Unidirectional Tapes
- PEEK (Polyetheretherketone)
- PPS (Polyphenylene Sulfide)
- PEKK (Polyetherketoneketone)
- PEI (Polyetherimide)
- LMPAEK (Low‑Melting Polyaryletherketone)
- Nylon
Fabric‑Based Prepregs
- PEEK
- PPS
- PEKK
- PEI
- Nylon
- Polypropylene
- Polyethylene
- PET (Polyethylene Terephthalate)
- LMPAEK
- Polycarbonate
'TORAY'
Toray Advanced Composites
Why Thermoplastics?
Thermoplastic Advantages
Material Properties
- High fracture toughness & high CAI (Compression‑After‑Impact)
- Excellent mechanical performance
- Recyclability
- Low flame, smoke & toxicity characteristics
- Room‑temperature storage capability
- Reprocessability
Low‑Cost Manufacturing
- High‑speed part production
• Thermoforming
• Compression molding
• Continuous Compression Molding (CCM)
• Advanced Automated Fiber Placement (AFP)
- Fast part joining
• Welding
• Integrated structural design
PRESENTED BY ACMA Composites
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Large‑Scale Adoption of Thermoplastic Composites
Toward cost‑effective, weight‑optimized structures
Adoption of thermoplastic composites for commercial aerospace is accelerating
Adoption‑phase timeline:
1. TP Concept Validation Phase
Validate TP technology on secondary‑structure components
2. Thermoset Replacement & Production‑Rate Growth
Convert existing wide‑body‑aircraft thermoset parts to TP components, drive higher production rates
3. Primary Structures for Next‑Generation Aircraft
Next‑generation composite‑rich aircraft designs incorporate large amounts of TP materials
4. Broader TP Adoption
Wider‑spread implementation of thermoplastic composites
Application scopes: Fuselage, engine pylon, torque box, empennage, small‑aircraft wing
8ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace Thermoplastic‑Composite Parts
Current Applications
- Brackets & clips
- Aerial‑film components
- Leading‑edge structures
- Vertical stabilizers
- Window frames
- Overhead‑bin latch covers
- Aircraft seats
- Wing ribs
- Wingtips
- Environmental control‑system components
Future Target Applications
- Fuselage
- Wing skins
- Floor beams
- Radomes
PRESENTED BY ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace‑Part Manufacturing Processes
Primary Processes
- Automated Fiber Placement (AFP)
- Automated Tape Laying (ATL)
- Continuous Compression Molding
- Press forming
- Autoclave curing
- Vacuum forming
- Thermoforming / Stamping
- Vacuum‑Bag‑Only (VBO)
Secondary Processes
- Injection over‑molding
- Bonding
- Welding
- Painting
Machine photo labels:
Core
Infrared oven
Cavity
Blank
Shuttle Frame / holder
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Material Properties
Key material‑performance considerations
- Polymer selection
- Processing temperature
- Mechanical properties
- Solvent resistance
- Crystallization kinetics
- Polymer viscosity
- Toughness‑versus‑flow trade‑offs
• TC1225 (LMPAEK): Low melt viscosity with excellent toughness
- Prepreg quality
• Good fiber‑matrix distribution
• Consistent thickness across wide formats
• Low void content
Micrograph: Toray TC1225 / T700 prepreg
Good fiber‑matrix distribution, void‑free
Thinking question:
Why is T700 carbon fiber used for LMPAEK‑matrix composites, instead of higher‑strength T800 or T1100 fibers?
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Automated Fiber Placement (AFP)?
- Automated process for laying prepreg onto tooling with defined fiber orientation and ply lay‑up
Thermoplastic AFP
- In‑situ consolidation
Parts are fully consolidated upon removal from the tool
- Partial consolidation
Secondary consolidation process is required to eliminate part voids
- Suitable for complex parts, parts with ply drop‑off regions
- Heat sources: Hot‑gas torch, laser, UV / infrared lamps
Case reference: TAPAS 2 Pylon, May 2016
Video courtesy of NLR. Recorded for the TAPAS‑2 pylon project, 2016.
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on AFP Processing
TC1320 (PEKK)
- Difficult to produce void‑free laminates using AFP alone
- Good‑quality laminates achieved after subsequent VBO cure
AFP: High void content → After VBO: Void‑free good laminate
TC1225 (LMPAEK)
- High‑quality panels achievable with AFP only
- Root cause: Lower polymer melt viscosity of TC1225
AFP only: Void‑free → After VBO: Excellent‑quality laminate
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Laying TC1225 PAEK Tape
Material: Toray TC1225(LMPAEK)/T700GC
Evaluation of multiple lay‑down speeds
- 4 in/sec (100 mm/s)
- 8 in/sec (200 mm/s)
- 16 in/sec (400 mm/s)
Results:
Good composite quality at lay speeds up to 400 mm/s.
Robot dynamics and laser‑power limit further speed increases.
Some voids develop within the final ply at 400 mm/s.
Tool‑temperature study (fixed lay‑speed:16 in/sec = 400 mm/s)
- Room‑temperature tool
Low crystallinity, excellent consolidation
- 210 °F (100 °C) tool
Increased crystallinity, excellent consolidation
- 390 °F (200 °C) tool
Full crystallinity, deconsolidation‑induced porosity
- Room‑temperature tool + post‑anneal
Full crystallinity, excellent consolidation
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Mitigating Final‑Ply Porosity
Toray TC1225(LMPAEK)/T700GC, lay‑speed 16 in/sec (400 mm/s)
- Outer ply develops porosity
- Second compaction roller pass over the final ply eliminates porosity
Conclusion:
Compaction rollers can effectively consolidate multi‑ply stacks.
Image captions:
Outer ply — single roller pass
Outer ply — after second roller pass
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Vacuum‑Bag‑Only (VBO)?
- Out‑of‑autoclave processing solution
- Consolidate laminates using vacuum pressure plus applied heat
Advantages
- No high‑capital‑cost autoclave required; oven‑only solution typical
- Single‑sided tooling is sufficient
- Part size limited by oven / heating‑system footprint
Disadvantages
- Relatively long cure cycles
- Consumable‑material costs
Typical VBO bag‑assembly sequence
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Post‑lay‑down Oven Consolidation via VBO
Toray TC1225(LMPAEK)/T700GC
VBO / oven consolidation after tape laying
- In‑situ consolidation is not practical for certain complex geometries and ply‑drop‑off parts
- VBO / oven consolidation is a viable alternative
Relieves residual stress; increases crystallinity
Mechanical‑property performance comparable to autoclave‑ or press‑consolidated parts
Chart label: Original consolidation cycle
Micrograph caption: Void‑free
C‑scan image label: C‑scan
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on VBO Processing
VBO study on TC1225(LMPAEK)
Study objectives:
- Thick‑section laminates
Successfully processed 72‑ply (3/8 in / 10 mm) panels, 12 in × 12 in (300 mm × 300 mm)
- Short‑cycle cure development
Max temperature 625 °F (330 °C)
Heat‑up rate 9 °F/min (5 °C/min)
Cool‑down rate 5 °F/min (3 °C/min)
No isothermal hold step
Total cycle time: 3 hours
- Reduced consumable‑material usage
Study results:
Excellent laminate quality.
Micrographs confirm zero voids within laminate. (Dark features represent 90°‑oriented fibers, not voids.)
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Conclusions
Thermoplastic‑composite adoption
- Deployed across multiple aerospace‑platform applications
- Further adoption expected in future programs
- Expanding set of available manufacturing processes
- Continuous improvements in composite‑material performance
- Growing industrial‑supporting infrastructure
- Expanding toolkit for component and assembly manufacturing
Dan Leeser
Technology Manager, Thermoplastics
'TORAY'
Toray Advanced Composites
Original paper title: Advances in Understanding the Properties of Thermoplastic Composites
Compiled: Yang Chaofan, Aug 10, 2026THERMOPLASTIC COMPOSITES CONFERENCE
TCC 2020
A VIRTUAL EVENT
APRIL 29 ‑ MAY 1, 2020
Fundamentals of Thermoplastic Composites
Presented By: Daniel Leeser
Technology Manager, Thermoplastics
Toray Advanced Composites
PRESENTED BY ACMA Composites
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Toray — Thermoplastic Composite Matrix Supplier
Toray International
- Carbon fiber manufacturing
- Global leader in composite materials
Toray Advanced Composites (TAC)
- Thermoset prepregs & supporting materials
- Thermoplastic prepregs & supporting materials
- Compression‑molded components
Thermoplastic Composites
Unidirectional Tapes
- PEEK (Polyetheretherketone)
- PPS (Polyphenylene Sulfide)
- PEKK (Polyetherketoneketone)
- PEI (Polyetherimide)
- LMPAEK (Low‑Melting Polyaryletherketone)
- Nylon
Fabric‑Based Prepregs
- PEEK
- PPS
- PEKK
- PEI
- Nylon
- Polypropylene
- Polyethylene
- PET (Polyethylene Terephthalate)
- LMPAEK
- Polycarbonate
'TORAY'
Toray Advanced Composites
Why Thermoplastics?
Thermoplastic Advantages
Material Properties
- High fracture toughness & high CAI (Compression‑After‑Impact)
- Excellent mechanical performance
- Recyclability
- Low flame, smoke & toxicity characteristics
- Room‑temperature storage capability
- Reprocessability
Low‑Cost Manufacturing
- High‑speed part production
• Thermoforming
• Compression molding
• Continuous Compression Molding (CCM)
• Advanced Automated Fiber Placement (AFP)
- Fast part joining
• Welding
• Integrated structural design
PRESENTED BY ACMA Composites
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Large‑Scale Adoption of Thermoplastic Composites
Toward cost‑effective, weight‑optimized structures
Adoption of thermoplastic composites for commercial aerospace is accelerating
Adoption‑phase timeline:
1. TP Concept Validation Phase
Validate TP technology on secondary‑structure components
2. Thermoset Replacement & Production‑Rate Growth
Convert existing wide‑body‑aircraft thermoset parts to TP components, drive higher production rates
3. Primary Structures for Next‑Generation Aircraft
Next‑generation composite‑rich aircraft designs incorporate large amounts of TP materials
4. Broader TP Adoption
Wider‑spread implementation of thermoplastic composites
Application scopes: Fuselage, engine pylon, torque box, empennage, small‑aircraft wing
8ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace Thermoplastic‑Composite Parts
Current Applications
- Brackets & clips
- Aerial‑film components
- Leading‑edge structures
- Vertical stabilizers
- Window frames
- Overhead‑bin latch covers
- Aircraft seats
- Wing ribs
- Wingtips
- Environmental control‑system components
Future Target Applications
- Fuselage
- Wing skins
- Floor beams
- Radomes
PRESENTED BY ACMA
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Aerospace‑Part Manufacturing Processes
Primary Processes
- Automated Fiber Placement (AFP)
- Automated Tape Laying (ATL)
- Continuous Compression Molding
- Press forming
- Autoclave curing
- Vacuum forming
- Thermoforming / Stamping
- Vacuum‑Bag‑Only (VBO)
Secondary Processes
- Injection over‑molding
- Bonding
- Welding
- Painting
Machine photo labels:
Core
Infrared oven
Cavity
Blank
Shuttle Frame / holder
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Material Properties
Key material‑performance considerations
- Polymer selection
- Processing temperature
- Mechanical properties
- Solvent resistance
- Crystallization kinetics
- Polymer viscosity
- Toughness‑versus‑flow trade‑offs
• TC1225 (LMPAEK): Low melt viscosity with excellent toughness
- Prepreg quality
• Good fiber‑matrix distribution
• Consistent thickness across wide formats
• Low void content
Micrograph: Toray TC1225 / T700 prepreg
Good fiber‑matrix distribution, void‑free
Thinking question:
Why is T700 carbon fiber used for LMPAEK‑matrix composites, instead of higher‑strength T800 or T1100 fibers?
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Automated Fiber Placement (AFP)?
- Automated process for laying prepreg onto tooling with defined fiber orientation and ply lay‑up
Thermoplastic AFP
- In‑situ consolidation
Parts are fully consolidated upon removal from the tool
- Partial consolidation
Secondary consolidation process is required to eliminate part voids
- Suitable for complex parts, parts with ply drop‑off regions
- Heat sources: Hot‑gas torch, laser, UV / infrared lamps
Case reference: TAPAS 2 Pylon, May 2016
Video courtesy of NLR. Recorded for the TAPAS‑2 pylon project, 2016.
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on AFP Processing
TC1320 (PEKK)
- Difficult to produce void‑free laminates using AFP alone
- Good‑quality laminates achieved after subsequent VBO cure
AFP: High void content → After VBO: Void‑free good laminate
TC1225 (LMPAEK)
- High‑quality panels achievable with AFP only
- Root cause: Lower polymer melt viscosity of TC1225
AFP only: Void‑free → After VBO: Excellent‑quality laminate
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Laying TC1225 PAEK Tape
Material: Toray TC1225(LMPAEK)/T700GC
Evaluation of multiple lay‑down speeds
- 4 in/sec (100 mm/s)
- 8 in/sec (200 mm/s)
- 16 in/sec (400 mm/s)
Results:
Good composite quality at lay speeds up to 400 mm/s.
Robot dynamics and laser‑power limit further speed increases.
Some voids develop within the final ply at 400 mm/s.
Tool‑temperature study (fixed lay‑speed:16 in/sec = 400 mm/s)
- Room‑temperature tool
Low crystallinity, excellent consolidation
- 210 °F (100 °C) tool
Increased crystallinity, excellent consolidation
- 390 °F (200 °C) tool
Full crystallinity, deconsolidation‑induced porosity
- Room‑temperature tool + post‑anneal
Full crystallinity, excellent consolidation
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Mitigating Final‑Ply Porosity
Toray TC1225(LMPAEK)/T700GC, lay‑speed 16 in/sec (400 mm/s)
- Outer ply develops porosity
- Second compaction roller pass over the final ply eliminates porosity
Conclusion:
Compaction rollers can effectively consolidate multi‑ply stacks.
Image captions:
Outer ply — single roller pass
Outer ply — after second roller pass
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
What is Vacuum‑Bag‑Only (VBO)?
- Out‑of‑autoclave processing solution
- Consolidate laminates using vacuum pressure plus applied heat
Advantages
- No high‑capital‑cost autoclave required; oven‑only solution typical
- Single‑sided tooling is sufficient
- Part size limited by oven / heating‑system footprint
Disadvantages
- Relatively long cure cycles
- Consumable‑material costs
Typical VBO bag‑assembly sequence
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Post‑lay‑down Oven Consolidation via VBO
Toray TC1225(LMPAEK)/T700GC
VBO / oven consolidation after tape laying
- In‑situ consolidation is not practical for certain complex geometries and ply‑drop‑off parts
- VBO / oven consolidation is a viable alternative
Relieves residual stress; increases crystallinity
Mechanical‑property performance comparable to autoclave‑ or press‑consolidated parts
Chart label: Original consolidation cycle
Micrograph caption: Void‑free
C‑scan image label: C‑scan
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Polymer‑Matrix Effects on VBO Processing
VBO study on TC1225(LMPAEK)
Study objectives:
- Thick‑section laminates
Successfully processed 72‑ply (3/8 in / 10 mm) panels, 12 in × 12 in (300 mm × 300 mm)
- Short‑cycle cure development
Max temperature 625 °F (330 °C)
Heat‑up rate 9 °F/min (5 °C/min)
Cool‑down rate 5 °F/min (3 °C/min)
No isothermal hold step
Total cycle time: 3 hours
- Reduced consumable‑material usage
Study results:
Excellent laminate quality.
Micrographs confirm zero voids within laminate. (Dark features represent 90°‑oriented fibers, not voids.)
PRESENTED BY ACMA
www.acmanet.org
THERMOPLASTIC COMPOSITES CONFERENCE 2020
Conclusions
Thermoplastic‑composite adoption
- Deployed across multiple aerospace‑platform applications
- Further adoption expected in future programs
- Expanding set of available manufacturing processes
- Continuous improvements in composite‑material performance
- Growing industrial‑supporting infrastructure
- Expanding toolkit for component and assembly manufacturing
Dan Leeser
Technology Manager, Thermoplastics
'TORAY'
Toray Advanced Composites
Original paper title: Advances in Understanding the Properties of Thermoplastic Composites
Compiled: Yang Chaofan, Aug 10, 2026
