An efficient and cost-effective dry coating process was developed to deposit polymer powders on continuous fibers and produce thermoplastic matrix towpregs to be processed into composites. The technological solutions used in the coating line construction and the influence of the processing parameters on manufactured glass fiber reinforced polypropylene (GF/PP) towpregs are detailed in this paper. Composites were produced from characterized (GF/PP) towpregs using hot plate compression molding. The mechanical properties determined on the composites are compared with theoretical values predicted by the Classical Lamination Theory (CLT) using the experimentally determined raw material contents and tensile properties.

The present work reports the development of new technologies to fabricate long and continuous-fiber-reinforced composite structures from low-cost thermoplastic matrix semiproducts. These semiproducts, thermoplastic matrix towpregs and preconsolidated tapes (PCTs), were produced in a purposely-built prototype machine, by deposition of a thermoplastic polymer in powder form on continuous fibers. The work also presents the advances made in the processing of these materials into composites by conventional techniques, such as pultrusion, filament winding and compression molding. Finally, it describes the investigation of the optimal processing conditions that maximize the mechanical properties of the composites. These properties are good enough for the composites to be used as engineering materials in many structural applications.