Abstract A description of the hot‐melt prepreg process was developed by coupling resin matrix flow at the coating and impregnation zones with heat transfer considerations. Both bismaleimide (BMI) and epoxy resin systems were used as matrices. With continuous carbon fiber reinforcement. For the laboratory scale prepregger utilized in this study, the thickness of the resin film produced in a doctor blade was approximately 63% of the blade distance, showing good agreement with experimental data. In addition, the measured heat transfer coefficient between prepreg and atmosphere indicated that surface convective resistance is large compared to the internal conductive resistance and thus the chill plate in the prepregging operation plays on important role in determining prepreg quality. By formulating an analytical methodology in terms of the “Prepreg Flow Number” (PFN) that combined important operating parameter (e.g., temperature, pressure, and production rate), a temperature‐pressure‐velocity superposition was confirmed for the prepregging process. In addition, the model could easily be extended to different scales and types of prepregging processes with the aid of dimension‐less parameters that are quite descriptive of the operating conditions employed in prepreg manufacturing.