With thermoplastic matrix resins, on-line consolidation of continuous-fiber composite laminates offers the potential of eliminating the post-placement autoclave or oven curing step, thereby simplifying the process and reducing costs. The aim of the present work was to identify key variables in rapid weld-bonding of thermoplastic tow (ribbon) and their relationship to matrix polymer properties and to ribbon microstructure. Theoretical models for viscosity, establishment of ply-ply contact, instantaneous (Velcro) bonding, molecular ...