Based on the Plateau-Rayleigh instability mechanism, this study proposes a novel fabrication method for flexible thermoplastic composite prepreg yarns. Using this approach, we successfully prepared carbon fiber/polyether ether ketone (CF/PEEK) prepreg yarns with a unique ‘bead-on-string’ microstructure. The prepreg yarn simultaneously exhibits excellent flexibility and uniform resin distribution, effectively addressing the challenge of thermoplastic resin impregnation. Its superior pliability enables textile processing such as weaving and braiding, offering a novel strategy for developing multidimensional structural thermoplastic composites.
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