Abstract: With the development of launch vehicles toward lightweight design, high reliability, and reusability, rocket casings, as critical load-bearing structures, are subject to increasingly stringent requirements for structural weight reduction, manufacturing quality, and reliability under repeated service. Continuous carbon fiber-reinforced thermoplastic composites offer high specific strength and stiffness, weldability, and high forming efficiency, providing a new technological route for the lightweight design and efficient manufacturing of reusable rocket casings. In recent years, advances in in situ heating, automated filament winding, and robotic manufacturing have substantially increased the potential of continuous carbon fiber-reinforced thermoplastic composites for manufacturing complex casing structures. However, high-performance thermoplastic matrices generally exhibit high melting temperatures and narrow processing windows, while temperature, compaction pressure, fiber tension, and machine motion states are strongly coupled during in situ forming, which can lead to insufficient interfacial bonding, void defects, and unstable fiber placement. Moreover, continuous winding of complex casings, online monitoring of forming quality, and highly flexible automated manufacturing still lack sufficiently mature processes and equipment, thereby restricting the engineering application of these composites in reusable rocket casings. Accordingly, this review focuses on the key manufacturing issues of stable consolidation, accurate winding, quality control, and complex-structure forming for reusable rocket casings made of continuous carbon fiber-reinforced thermoplastic composites. Research progress in material forming mechanisms, in situ manufacturing processes, forming equipment and winding trajectory planning, as well as advanced hybrid forming technologies, is systematically reviewed. Major limitations in forming stability, manufacturing accuracy, process monitoring, and adaptability to complex structures are analyzed, and future directions toward intelligent in situ manufacturing, closed-loop quality control, and efficient automated forming of complex casings are discussed. This review is expected to provide a reference for the development and engineering application of manufacturing technologies for reusable rocket casings made of continuous carbon fiber-reinforced thermoplastic composites.