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This paper presents a parameter study into the thermoplastic-automated fibre placement process. The material used was carbon fibre-reinforced LM-PAEK unidirectional tape. The overall objective of this investigation was the derivation of regression models to describe and predict the consolidation quality of laminates in dependence on the main process parameters of the lay-up process. Furthermore, post-consolidation by stamp forming was investigated to analyse the impact of the initial quality of the blank on post-forming laminate quality. With the parameter study performed, prediction models for the degree of bonding and crystallinity could be derived. In addition, a more comprehensive understanding of the process parameter influences and the definition of parameter limits to distinguish between rapid and in situ lay-up processes was achieved. Furthermore, the potential of the process chain consisting of rapid lay-up and stamp forming for producing high-quality laminates was demonstrated for the investigated LM-PAEK tape.
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