Abstract: A coated tow includes a fiber bundle composed of continuous reinforcement fibers that form a flat substrate in a ribbon shape and a thermoplastic-based overcoating applied to the flat substrate to form a uni-directional tape. An extruded tape includes a plurality of cords of twisted fiber yarns each composed of continuous reinforcement fibers, a thermoplastic overcoating applied to each of the cords, and a high density polyethylene (HDPE) that encases the plurality of cords to form a uni-directional tape. The reinforcement fibers have continuous filaments aligned lengthwise along a length each of the cords. A process of producing the coated tow or extruded tape includes feeding one or more spools of continuous fiber tow under tension control, sinking the continuous fiber tow in a chemical bath, passing the wetted continuous fiber tow through one or more squeezing rollers, and passing the continuous fiber tow through an oven.

Abstract: A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

Abstract: A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.