Methods of producing thermoplastic composites using fabric-based thermoplastic prepregs

A thermoplastic product comprising:

• a main body comprising:
• a fabric-based reinforcing sheet that is wound about a mandrel to form a plurality of layers of the fabric-based reinforcing sheet having a cross-sectional shape corresponding to the mandrel, the fabric-based reinforcing sheet including a plurality of fiber bundles;
• and
• a polymerized thermoplastic material within each layer of the fabric-based reinforcing sheet, the polymerized thermoplastic material bonding each layer of the fabric-based reinforcing sheet to an adjacent layer of the fabric-based reinforcing sheet;
• wherein the plurality of layers of the fabric-based reinforcing sheet and the polymerized thermoplastic material form a unitary thermoplastic product.

A thermoplastic product comprising:

• a main body comprising:
• a plurality of layers of a woven fabric reinforcing sheet having a shape that corresponds to a substrate or a mold, each layer of the woven fabric reinforcing sheet including a plurality of fiber bundles that are oriented according to a first direction and a second direction having an angled orientation relative to the first direction;
• and
• a polymerized thermoplastic material that is saturated within each layer of the woven fabric reinforcing sheet such that the polymerized thermoplastic material fully impregnates each fiber bundle of the plurality of fiber bundles, the woven fabric reinforcing sheet and the polymerized thermoplastic material forming a unitary thermoplastic product.