The excellent mechanical properties, wide usage temperature range and secondary processing possibility make continuous fiber reinforced thermoplastic prepreg develop rapidly. The hot-melt method is an accurate and efficient thermoplastic prepreg molding method. It is an engineering problem that needs to be solved that how to achieve the uniform and full impregnation of continuous fiber bundles with high viscous resin melts, such as PPS, PEEK and so on. Firstly, based on Darcy’s law, four impregnation theoretical models were proposed, which fully consider the effects of process temperature, pressure, processing stage and shape of fiber bundles on impregnation, and they can provide theoretical guidance for the establishment of continuous fiber reinforced thermoplastic prepreg production lines and the determination of process parameters. Then the research and industrialization status of domestic and foreign continuous fiber reinforced thermoplastic prepreg are compared: foreign related industries have a wide range of prepregs, which have been widely used in military aircraft, civil aircraft and other fields, but foreign company have a strict purchase policy for China. Domestic demand for continuous fiber reinforced high performance thermoplastic prepreg is in short supply. Beihang thermoplastics group has independently developed a continuous fiber reinforced high performance thermoplastic prepreg production line via hot melting method, which has eased domestic urgency to some extent.