A statistical approach was utilized to analyze the electrostatic powde
r prepregging process. A Plackett-Burman screening design was employed
to identify electrostatic voltage, tow speed, and fluidization veloci
ty as the key system variables. A face centered cubic response surface
design, using a second-order linear regression analysis, modeled the
impact of the three variables, and the impact of their interaction, on
the key dependent variable of towpreg resin volume fraction. Subseque
nt verification experimental runs show good agreement with the model.