This paper presents some current results of manufacturing advanced composite components for a civil aircraft by compression moulding process using a carbon fibre fabric reinforced polyetherimide composite (CF/PEI). Effects of processing conditions on the consolidation quality and mechanical properties of CF/PEI composite are studied. A qualitative model to describe the impregnation and consolidation processes of this material was developed, with which an optimum processing window was established. The spring-in effect was taken into consideration in the design of processing mould system. Thermoplastic composite demonstration parts, aileron ribs and high load hinges were successfully produced according to the optimum processing window.