A project was launched to research and develop a novel high-speed diaphragm-forming process for the efficient manufacture of reinforced thermoplastic components. The composite materials are made from two main constituents such as a reinforcement, commonly glass, which provides the structural properties, and a resin, which transfers stresses and strains between the reinforcing fibres. The diaphragm-forming involves molding a thermoplastic component between two extensible rubber membranes using air pressure. The new diaphragm forming process will now enable more producers to use thermoplastic composite materials and take advantage of their inherent benefits and sustainability.