Papiya Bhowmik, Harshit Sharma, Gaurav Arora, Mohit Kumar, Babita Dhiman, Vinod Ayyappan, Manoj Kumar Singh, Ravi Sevak, Sanjay Mavinkere Rangappa, Suchart Siengchin
Thermoplastic composites have emerged as advanced engineering materials due to their superior recyclability, damage tolerance, and processing versatility compared with conventional thermoset systems. This review provides a comprehensive assessment of recent advances in thermoplastic composite materials, with particular emphasis on matrix and reinforcement selection, advanced processing technologies, recyclability, and performance-related challenges. Key manufacturing approaches such as compression molding, thermoforming, automated tape placement, and in-situ consolidation are critically discussed, highlighting their advantages, limitations, and influence on microstructural integrity and mechanical performance. The review further examines sustainability aspects through life cycle assessment, renewable feedstocks, and end-of-life management strategies, positioning thermoplastic composites as promising candidates for circular economy-driven applications. Despite these advantages, long-term durability issues remain significant, particularly under dynamic loading, environmental exposure, and hygrothermal conditions. Challenges related to viscoelastic damage evolution, interfacial bonding, moisture sensitivity, and residual stress development are also discussed. Finally, the review identifies existing research gaps and outlines future directions focused on interfacial engineering, advanced process control, data-driven modeling, and sustainable material design to enable reliable large-scale adoption of thermoplastic composites in automotive, aerospace, marine, and construction sectors.