Continuous fiber-reinforced thermoplastic composites are emerging as an efficient structural alternative to traditional thermoset materials, thanks to their recyclability, good impact resistance, and suitability for continuous processing. In this work, a manufacturing system was developed based on the thermoplastic pultrusion of unidirectional polypropylene (PP) and carbon fiber (CF) tapes, followed by hot compression molding. This approach enables the production of structural profiles with high fiber alignment and good consolidation. Experimental characterization included tensile, flexural, and impact tests to assess the structural applicability of the manufactured profiles. The results demonstrate a balanced combination of stiffness, mechanical strength, and impact performance, confirming the potential of this system for functional applications in sectors such as mobility or infrastructure, where lightweight, efficient processing, and sustainability are key requirements.
Abstract Continuous fiber-reinforced thermoplastic composites are emerging as an efficient structural alternative to traditional thermoset materials, thanks to their recyclability, [...]