Fiber-reinforced thermoplastic polymers are being considered as alternatives to thermoset composites because they are recyclable, easier to repair, less hazardous to produce, and offer better impact resistance. However, high material costs and processing challenges hinder their widespread adoption in high-performance applications. Continuous Resistance Heating Technology (CoRe HeaT) is an innovative method for the rapid processing of continuous fiber prepreg tapes, aiming to accelerate manufacturing and reduce costs. This study examines how process parameters such as moisture, maximum temperature, heating rate, and tape tension affect CoRe HeaT deconsolidated carbon fiber low-melt polyaryletherketone (CF-LMPAEK) prepreg tapes. It also investigates how consolidation parameters, such as average compaction pressure, compaction duration, tape tension, and tooling temperature, influence the quality of CF-LMPAEK pipe preforms produced using high-speed (500 mm/s) CoRe HeaT tape winding. Image processing of cross-sectional micrographs are used to quantitatively evaluate both deconsolidated tapes and wound preforms. Void content, root mean square surface roughness and waviness, and pore distribution are used as indicators for tape and laminate quality, since they can have significant impacts on mechanical performance, durability, and further stages in product manufacturing. The deconsolidation of tape is performed by heating a 70 cm long, pre-tensioned CF-LMPAEK tape clamped between two double-plate electrodes using one electrical pulse. The oven-dried tape had a 40% lower porosity as compared to the tape kept at ambient conditions. A tenfold increase in tension could also be seen to decrease porosity by 25%. Temperature and heating rate were linked in pore proliferation, while temperature alone was seen to be critical to roughness increases. A lack of tow tension was seen to cause global wrinkling of the tape, increasing waviness by 62%, while excessive tensioning was correlated with a decrease in tape width by 6.4%. The preform winding is performed using a purpose-built tape winding machine and consolidated using custom-built pressure elements, spanning rigid and conformable rollers and area compactors. The rate of porosity increase with an increase in compaction duration was seen to be negatively correlated with the applied compaction pressure. The lowest level of volumetric void content of 0.75% was achieved with the use of a silicone area compactor at 1.22 MPa within the preform tubes wound at 500 mm/s. The lowest levels of roughness and waviness, of 2.27 μm and 9.5 μm, respectively, were obtained using a a copper roller delivering 4.56 MPa at 500 mm/s winding speed. Compaction pressure was linked to a power fitting decrease in porosity. Increasing tension was also connected to a decrease in porosity, yet excessive tensioning led to gap widening, ineffective gap filling, and layer crumbling, which negatively impacted laminate quality. A marginal improvement in outer surface quality could be linked to heating the tooling above the glass transition temperature (Tg ) of LMPAEK. The impact of increasing tooling temperature on porosity and pore distribution was negligible. It was concluded that further optimization of conformable area compactors may bring significant improvements in laminate quality for winding speeds exceeding 500 mm/s, and should be further studied. Furthermore, additional studies on the impact of tape temperature at the nip-point are expected once sufficient temperature monitoring and control capabilities are achieved.