This paper details the development of a composite manufacturing process that uses an electrostatic powder spray technique to impregnate a continuous fibre tow with a thermoplastic polymer. The resulting towpreg undergoes intermediate forming to induce further wetout of the fibres by the polymer matrix. An on-line filament winding apparatus then consolidates the towpreg into a finished cylinder. Experimental results detail the effects of key spray coating parameters such as electrostatic corona voltage, powder velocity, and powder mass flowrate. The process demonstrates its effectiveness in coating and consolidating a variety of materials, including E-glass, S-glass, and carbon fibres.
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