Investigations of the tape placement process are still underway to achieve the laminate quality comparable with other highly developed composite manufacturing methods, such as autoclave-based processes. The evaluation of the products and the mechanical properties of the material has revealed regions where some upgrading could bring significant enhancement in performance. This study is concerned with issues related to the characterization of material properties, interlaminar bond development, and ways of optimizing process parameters. These include heating, layup velocity, tool temperature, and consolidation force, which were studied to determine their effects on the mechanical strength of the composites produced. The bonding degree of the laminates was simulated taking into account a combination of process parameters, comparing the predictions with the actual test results. The thermal stability of the polyether ether ketone matrix, in relation to the processing conditions used in the manufacture, and their effects on the interlaminar bonding stability were also investigated and explained. (C) 2010 Wiley Periodicals, Inc. Adv Polym Techn 29: 98-111, 2010; Published online in Wiley lnterScience (www.interscience.wiley.com). DOI 10.1002/adv.20177