Abstract: Fiber areal weight (FAW) and resin mass fraction are critical material parameters governing the quality of in-situ consolidation in laser-assisted automated fiber placement of thermoplastic composites, as they strongly influence interlaminar heat transfer and resin flow behaviour. In this study, carbon Fiber-reinforced polyether ether ketone (CF/PEEK) prepregs were investigated using embedded thermocouples to monitor the temperature history during placement. Combined with microstructural observation, quantitative porosity analysis, crystallisation characterisation and mechanical testing, the effects of FAW and resin mass fraction on interfacial bonding, pore evolution and mechanical performance of in-situ consolidated laminates were systematically examined. The results show that increasing FAW increases single-ply thickness and extends the heat transfer path in the thickness direction, thereby shortening the effective interlaminar melting time and weakening interfacial bonding. Consequently, laminate porosity increases from 0.20% to 2.48%, accompanied by significant reductions in both flexural strength and interlaminar shear strength. Increasing the resin mass fraction improves resin filling and gas evacuation at the interface, reducing porosity from 1.35% to 0.13%. However, further increases in resin mass fraction lead to reduced flexural performance due to the decreased Fiber load-bearing fraction and localised resin enrichment, while crystallinity decreases from 39.2% to 31.4%.Experimental results indicate that optimal performance is obtained at a fiber areal weight of 147 g/m² and a resin mass fraction of 29.9%, where the CF/PEEK in-situ consolidated laminate achieves an interlaminar shear strength of 93.64 MPa and a porosity of 0.72%, well below the 1% porosity requirement for aerospace structural components.