Thermoplastics (TP) are high molecular weight polymers which, unlike thermosetting (TS) resins, do not form a rigid three-dimensional cross-linked chemical structure after processing. This allows the TP to be readily re-melted and re-formed, not the TS. Additional advantages are: chemical/impact resistance, range of temperatures, low level of moisture uptake then low hot/wet conditions degradation, eco-friendly/reusable properties that can make them a primary selection when the part life cycle is considered.

In situ consolidation automated processes with TP (ISC/TP) are currently at a level of development that does not allow efficient series production of complex TP components. More research was still needed to manufacture double curvature panels including strong thickness changes, plies drop-off, etc. Disadvantages for a good industrialisation were: difficult process management, high process temperatures and pressures, material handling for an efficient ISC/TP process.

The four main drivers of the ISINTHER project were:

• To assess an in situ consolidation process for TPM orientated to industrial outcome
• To apply the above main guidelines for trials and demonstrators manufacturing
• To investigate on repair solutions and process to restore nominal quality of parts
• To assess the potential benefit impact of the ISC/TP process in terms of environment, costs and elongated life cycle.

The project work plan was supported on a strong collaboration of a Technology Center (FIDAMC) with an experimented Automation Manufacturer (MTorres) able to transfer their experience to ISC/TP process.

PEEK APC2-AS4 was the material reference but open to evolution or new materials. Reparability was another aspect to be investigated with a high budget and mechanical tests.

Finally, process eco-assessment was a key objective of the ECODESIGN ITD, widened here to the concept of process sustainability (environment plus cost efficiency) to see if ISC/TP could be the preferred selection.