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Based on some assumptions, this study derives an equation that estimates the theoretical molding thickness hc of knitted fabric reinforced thermoplastic composites (KFRTC). This is required for controlling the actual molding thickness of KFRTC that are produced by hot pressing knitted preforms made from reinforcing fiber/matrix fiber commingled yarns. The relationship between the optimum actual molding thickness h that can result in composites with higher tensile strength and lower void content and the theoretical molding thickness hc are also determined experimentally in this study. It is found that the composites produced can have higher tensile property and lower void content when h and hc satisfy h = khc (0.85 ≤ k ≤ 0.95). This estimation of h contributes to manufacturing KFRTC. [ABSTRACT FROM AUTHOR]