Computational modeling of variability in tensile properties of discontinuous prepreg platelet composites manufactured from trim edge tape

Trim Edge Tape (TET) is a by-product of unidirectional thermoplastic-based prepreg tape manufacturing. Converting TET into platelets (which exhibit a statistical distribution of size and shape) enables its use as a compression-molding compound, avoiding disposal of high-quality constituent material. This study examines the tensile behavior of TET-based carbon fiber reinforced PEEK prepreg platelet molded composites (PPMC/TET) using a meso-scale computational model that uses TET platelet statistics as inputs to a finite element progressive failure analysis. Repeated sampling of this probabilistic space allows evaluation of effective tensile stiffness, strength, and their statistical scatter. The mechanics of deformation and failure are examined through matched experimental and virtual tensile tests. Both reveal coupled deformation and formation of distributed damage process zones driven by through-thickness stress gradients. PPMC/TET shows the same deformation sequence as conventional PPMCs made from constant-size platelets, but exhibits higher mean strength and broader variability due to its lower platelet count per coupon and the larger influence of the upper tail of the platelet-size distribution. The validated framework demonstrates that platelet-geometry statistics can be used to predict effective tensile response and variability.