Continuous fibre reinforced thermoplastic plastics (CoFRTP) exhibit the advantages of fast manufacturing

high fracture toughness and high recyclability

which are promising materials for aerospace and automotive industries. Thermoforming process is one of the most promising way for CoFRTP forming since the advantages of high efficiency and low cost. However

due to the amount of forming parameters involved in this process and the complex coupling of factors such as large nonlinearity deformation and multi phase transformation of materials

defects like wrinkles

fiber cracking and excessive dimensional deformation are prone to be induced

which generate great challenges to the mechanical properties of components and the assembly property. In order to overcome the disadvantages of low efficiency and high cost of traditional trial and error methods and improve the efficiency of thermoforming process design

this paper focuses on the review of thermoforming process and numerical methods. This paper includes four parts: the application and manufacturing of CoFRTP

the analysis and research status of thermoforming process

the simulation method of thermoforming process as well as the conclusion and the outlook of thermoforming technology. This study will provide theoretical guidance for highly efficient and high quality forming of CoFRTP

and promote the corresponding structural design and engineering application as well.