EFFECT OF BLANK CONSOLIDATION LEVEL ON PROPERTIES OF CARBON-FIBER REINFORCED THERMOPLASTIC STAMP-FORMED PARTS

This paper investigates the impact of consolidation level in thermoplastic composite blanks on the final properties of stamp-formed parts. Stamp forming of thermoplastic composites has gained popularity in manufacturing due to its rapid processing capabilities, aligning with industry demands for reduced cycle times. However, current practices typically involve fully consolidating laminates prior to stamping, potentially extending overall production time. Through a series of experiments varying consolidation parameters, this study analyzes how different levels of pre-consolidation affect forming behavior, void content, and ultimately, the mechanical performance of the final part. The results of this investigation may provide insights into optimizing the balance between processing efficiency and part quality, potentially enabling manufacturers to streamline production while maintaining desired material properties.