High Speed AFP of Thermoplastics

Today, large aircraft components rely on automated fiber placement (AFP) followed by an autoclave cure. High-speed AFP processing has proven very effective for insitu layup using thermoset materials on latest generation AFP equipment. There remains, however, a substantial opportunity to utilize thermoplastic prepregs for large structural components in commercial aircraft. Thermoplastics have an advantage with the elimination of uncured resin build-up, which hurts AFP reliability and productivity. This advantage hasn�t been realized because most thermoplastic research has centered around insitu consolidation intending to eliminate post-processing for curing. This places all the demands on the AFP process to achieve final part quality (low porosity and crystallinity). The main disadvantage of insitu consolidation is the speed (and productivity) of the AFP process is limited by the physics of thermoplastic materials. In addition, the AFP process is sensitive to the quality of the raw material, which can vary greatly. Current advances in materials and AFP technology can greatly increase the productivity of thermoplastics for large structural components. High-performance thermoplastic prepreg tapes have mechanical, physical, and chemical resistance properties typical of the Polyaryletherketone (PAEK) polymers, such as PEEK, but with lower crystalline melting temperature. Advances in AFP technology, such as new heating technology, Variable Spot Size (VSS) laser, has enabled the AFP processing of thermoplastics with individual tow heating. There are new Out-of-Autoclave (OoA) post-processing methods that can achieve the proper crystallinity. By implementing these advances together with high speed AFP processing, the advantages of thermoplastic materials can be realized for large structural parts. Session summary Advances in AFP technology, such as new heating technology, Variable Spot Size (VSS) laser, has enabled the AFP processing of thermoplastics with individual tow heating. Advances in high-performance thermoplastic prepreg tapes have lowered processing temperatures. New Out-of-Autoclave (OoA) post-processing methods can achieve the proper crystallinity. By implementing these advances together with high speed AFP processing, the advantages of thermoplastic materials can be realized for large structural parts.