Researchers demonstrated an infrared-assisted automated fiber placement system for carbon fiber polycarbonate composites. Unlike laser-based systems, the infrared lamp is cheaper and still delivers enough heat for good bonding between layers. The study found that compaction force and tool temperature are the key variables for making strong laminates, with optimized parts showing improved flexural and lap-shear strength. The team also laid carbon fiber tows onto a 3D printed polyetherimide mold, avoiding the need for expensive machined metal tooling. That points to a cheaper workflow for low-volume parts like drone frames, automotive panels, and enclosures. The process runs out of autoclave, cutting energy use, and the thermoplastic matrix can be remelted for recycling at end of life. This matters because it could make carbon fiber composites more practical for mid-volume products where weight reduction matters but aerospace-grade costs don't. The trade-off is that polycarbonate-based parts are semi-structural, not for primary load-bearing use. Still, for the right applications, the combination of IR heating and printed molds lowers the entry barrier for lighter, more efficient parts.
