Laser-assisted automated lay-up process and mechanical properties of domestic CF/PEEK prepregs

CF/PEEK composite are strategic materials suitable for extreme environments. However, the difficulty in processing PEEK resin, the immaturity of domestic prepreg preparation and automated placement technology restrict its widespread engineering application. This study systematically investigates the preparation and lay-up processes of domestically produced CF/PEEK prepreg using self-developed prepreg pulling equipment and an automated fiber placement platform. First, CF/PEEK prepregs are fabricated via the powder impregnation method. Subsequently, orthogonal experiments are conducted to evaluate the effects of lay-up temperature, pressure and speed on the properties of the fabricated components. The results demonstrate that the prepared prepreg meets the requirements for automated lay-up. The influence of process parameters on part performance follows the order: temperature > lay-up speed > pressure. The optimal parameter combination is identified as: laser power of 220 W, pneumatic pressure of 0.3 MPa and lay-up speed of 101 mm/s. Under these conditions, the composites achieve an interlaminar shear strength of 55.7 MPa and a tensile strength of 2006.4 MPa, reaching 84.7% and 86.7% of the performance of hot-pressed counterparts, respectively, with a porosity of 3.4%. By comparing with relevant foreign research, the underlying causes of performance gaps are analyzed. This study provides reference for the systematic development of domestically produced materials, equipment and process technologies.