Facilitating aqueous powder impregnation for manufacturing thermoplastic composites: A prepreg rig design and process optimisation

This study investigates a novel thermoplastic prepreg rig and method of manufacturing prepregs using aqueous wet powder impregnation. The compact, easily maintained prepreg rig is suitable for rapid prepreg manufacturing in laboratory-scale research. The rig could be used with a wide range of thermoplastic powders and reinforcing fibres. Tests were conducted to study various settings and parameters, including the polymer–carrier ratio, winding speed and fibre tension. The study examined the effectiveness of the liquid carrier in suspending the polymer powder and tested the consistency of the rig in resin pick-up. The findings indicate that a winding speed of 4.2 to 5.7 m/min with a low fibre tension is ideal for producing S2-glass/PAEK prepregs. The amount of polymer pick-up by the fibre tow remained constant throughout the winding for 10, 20, and 30 wt% slurries. However, higher wt% slurry settings resulted in resin agglomeration on the rollers, causing significant fibre breakage.