An Overview of Thermoplastic-Based Composites: A Multi-Scale Approach from Material to Assembly Properties

Thermoplastic-based composites have emerged as promising materials for high-performance and sustainable applications across various industries. This study presents a multi-scale approach to understanding their behavior, from intrinsic material properties to the performance of assembled structures. Key advancements include the characterization of mechanical, thermal, and rheological properties, alongside innovative processing techniques such as laser welding, infrared heating, and additive manufacturing. The optimization of these processes is discussed in relation to enhancing composite properties and ensuring reliability in end-use applications. Additionally, non-destructive testing methods, including infrared thermography and digital image correlation, are explored for their efficiency in detecting defects, analyzing damage, and predicting fatigue behavior. This work aims to bridge experimental and numerical approaches, providing a comprehensive framework to guide the design, manufacturing, and application of thermoplastic composites. These findings contribute to advancing the scalability and implementation of these materials in engineering solutions, addressing both performance and sustainability challenges.