Polymer composites have been widely used in the aviation, aerospace, automotive, military, medical, agricultural and industrial fields due to their excellent mechanical properties, heat resistance, flame retardant, impact resistance and corrosion resistance. In general, their manufacturing process is one of the key factors affecting the life cycle of polymer composites. This article provides an overview of typical manufacturing technologies, including surface coating, additive manufacturing and magnetic pulse powder compaction, which are normally used to reduce the failure behaviour of polymer composites in service so that the quality of composite products can be improved. Advanced polymer composite powder manufacturing processes, the processing mechanism and experimental methods are described, and the influence of different manufacturing processes on the moulding quality is revealed. This investigation can provide suitable methods for the selection of manufacturing technology to improve the quality of polymer composite products.

The cold compaction of poly (ether ketone ketone) (PEKK) powder was studied by experiments and simulations based on the modified Doraivelu model. Although this model can successfully predict the compaction behavior of metal powders, discussion of the prediction of polymer powders is lacking. Based on the mechanical theory of metal plasticity, the modified Doraivelu model was established by introducing the material parameters m and n. The modified model can predict the compaction density of PEKK powder during cold compaction. A sub-increment method for this constitutive model was then established and implemented into a finite-element model by using the user-defined material subroutine UMAT in ABAQUS/Standard. Consequently, the material parameters of the modified Doraivelu model were identified by an inverse method using the experimental data and simulation results. It was found that when m = 0, n = 4, and the initial relative density was 0.4485, the simulation results were the closest to the experimental ones.

The light weight, electrical conductivity, environmental friendliness, and high mechanical properties of graphene/PEKK composites make them popular in biomedical, electronic component and aerospace fields. However, the compaction density and carbonization of the specimen influence the microstructure and conductivity of the graphene/PEKK composite prepared by in situ polymerization, so electromagnetic-assisted molding was used to manufacture products to avoid carbonization and enhance the compaction density. The effects of different discharge voltages on the microstructure of the formed graphene/PEKK specimens were compared. Increasing the discharge voltage will lead to a closer distribution of flake graphene in the matrix to improve the compaction density, mechanical performance and conductivity. At the same time, the numerical analysis model was validated by comparison with the compaction density of the experimental results. Based on this research, the stress/strain distribution on the specimen was obtained with increasing discharge voltages.

During the moulding process of polymer composite powders, carbonisation often occurs owing to the insufficient ability to control temperature, thereby affecting the service performance of parts. This research studies the electromagnetic moulding (EM) of polymer powders at room temperature and demonstrated the deformation behaviour of poly(ether-ketone-ketone) (PEKK) powder particles for aviation under high-speed impact during EM. The orthogonal analysis method showed that the PEKK powder with a mass of 0.4 g had the highest compaction density of 1.242 when the discharge voltage was 8 kV. Discharge voltage was the most important parameter affecting compaction density, as discharge voltage increases, compaction density increases, but the mass is the opposite. The microstructure and hardness distribution in the specimens further demonstrate that discharge voltage is an important parameter affecting compaction density and provide process guidance for obtaining the high relative density of polymer products.