Thermoplastic tape placement process - in situ consolidation is reachable

The aerospace industry is looking for highly efficient and fully automated processes to manufacture large structural components. Placement processes are fulfilling these requirements. Furthermore, they allow to lay up the structure with the highest degree of fibre orientation and well defined fibre position. Already in service are thermoset tape based placement processes. Main disadvantage is the need to have a consolidation process after structure lay-up has finished. Additionally, the required autoclave limits the component size. The thermoplastic tape placement process offers new possibilities. Fully impregnated fibre reinforced thermoplastic tapes are laid onto a mould to build up curved or flat structures step by step. Each tape is melted by a heat source, welded to the layer below, compressed by e. g. a roller, and cooled down below melting temperature. If this is done properly, an in situ consolidation can be achieved, which means no additional consolidation process is needed. The paper is giving an overview about thermoplastic tape placement process and elaborates the requirements to reach in situ consolidation.