Kim, Eunjung Cheon, Jinsil Yu, Woong-Ryeol Ahn, Cheol-Hee Na, Wonjin 2025-11-19T02:05:51Z 2025-11-19T02:05:51Z 2025-11-17 2026-01 1359-8368 https://pubs.kist.re.kr/handle/201004/153530 Conventional metal tooling for thermoplastic composite processing has a high density and thermal mass, resulting in long cycle times that exceed 60 min. This work presents a rapid forming approach using induction-heated carbon fiber-reinforced plastic (CFRP) molds with low thermal mass and minimal thermal expansion. However, the anisotropic and low thermal conductivity of CFRP causes significant non-uniform heating with conventional spiral coils. To address this issue, a ‘zig–spiral’ hybrid coil pattern was designed through coupled electromagnetic–thermal simulations, reducing temperature variation to below 6 °C, even for curved geometries. The coil design was experimentally validated through vacuum-bag forming of 3.3 mm-thick commingled yarn PP/GF laminates, resulting in uniform consolidation. Using this process, the total cycle time was reduced to 19 min (68 % faster than compression molding), and the tensile and flexural strength were maintained at 95 %. These results demonstrate the viability of induction-heated CFRP tooling as an efficient and scalable solution for manufacturing thermoplastic composites. English Pergamon Press Ltd. Rapid forming of commingled thermoplastic composites via induction-heated CFRP molds Article 10.1016/j.compositesb.2025.113120 3 Composites Part B: Engineering, v.310 Composites Part B: Engineering 310 N 001607491300002 Engineering, Multidisciplinary Materials Science, Composites Engineering Materials Science Article Induction heating Coil pattern optimization Finite element analysis CFRP mold Thermoplastic composite Rapid processing