Thermoplastic mono-polymer composite sandwich structures with honeycomb cores present a promising solution for lightweight applications in aircraft cabin interiors, offering advantages such as reduced production cycle times and enhanced recyclability. Unlike conventional thermoset-based structures, these mono-material systems enable adhesive-free bonding, simplifying recycling and material traceability. This study investigates the optimal manufacturing process for such structures, focusing on key parameters that influence product quality and mechanical performance. The research encompasses theoretical, numerical, and experimental analyses to address challenges in thermoforming, including achieving sufficient skin-core bonding while preventing core overheating. A process window is defined for three manufacturing approaches, isothermal, non-isothermal, and combined, based on heat transfer modeling and validated through experiments on flat and curved panels. Bonding mechanisms are further explored using a theoretical model and microscopic analysis, revealing distinct interface formations that affect bonding quality across methods. Mechanical characterization quantifies the impact of process parameters on final product performance. Additionally, thermomechanical analysis is employed to predict and mitigate defects such as wrinkling, buckling, and shape instability. The outcome is a refined process window that supports the reliable production of high-quality thermoplastic mono-material sandwich structures, contributing to sustainable and efficient aerospace manufacturing.
