Composites manufacturing is characterized by many degrees of freedom. Different materials, geometries and thermo-dynamical conditions contribute to a behavior that is difficult to predict. Monitoring the running process (in-line monitoring) eliminates the need for prediction; real time data provided by appropriate sensing systems can be used in the direction of process optimization, quality upgrade or material characterization. The aim of the review at hand is to record and discuss the latest progress in the field of in-line composites monitoring with a focus on Fiber Reinforced Polymericbased (FRP) composite structures. Summaries of each sensor’s principles of operation, appropriate association with polymer/composite properties detection, brief descriptions of representative studies, a critical overview of implementation aspects and discussion on the upcoming trends, contribute in constructing a complete picture

Thermoplastic tape placement with in situ consolidation is a unique process, in which prepreg tape is precisely positioned, laid-up and immediately consolidated on the tool surface in a single step. This study addresses some of the remaining issues that restrict the industrialisation of the thermoplastic tape placement. The consolidation quality of the laminates depends on several parameters underlying the consolidation mechanism, for example the tape placement setup, the processing parameters, and the material characteristics. In order to identify the critical parameters of the process, simulations were carried out to study the process sensitivity on individual parameters.

Laminated composites are increasingly used in aeronautics and the wind energy industry, as well as in the automotive industry. In these applications, the construction and processing need to fulfill the highest requirements regarding weight and mechanical properties. Environmental issues, like fuel consumption and CO₂-footprint, set new challenges in producing lightweight parts that meet the highly monitored standards for these branches. In the automotive industry, one main aspect of construction is the impact behavior of structural parts. To verify the quality of parts made from composite materials with little effort, cost and time, non-destructive test methods are increasingly used. A highly recommended non-destructive testing method is thermography analysis. In this work, a prototype for a car’s base plate was produced by using vacuum infusion. For research work, testing specimens were produced with the same multi-layer build up as the prototypes. These specimens were charged with defined loads in impact tests to simulate the effect of stone chips. Afterwards, the impacted specimens were investigated with thermography analysis. The research results in that work will help to understand the possible fields of application and the usage of thermography analysis as the first quick and economic failure detection method for automotive parts.