Introduction to Composites Manufacturing

Alfred C. LoosMechanical Engineering Department

Michigan State UniversityEast Lansing, MI 48824-1226

Objectives

• To combine reinforcing fibers with a resin matrix to form a structure with the desired properties.

• Optimal processing will result in composite parts:– Fully consolidated– Void free– Uniform matrix properties– Desired fiber/resin content– “Best” properties– Processed in the shortest amount of time

Glass Fiber

PREPREGGING TECHNIQUES

Prepreg

Wetlay Paper Making Process

U.S. Patent 5,409,573

Dewatered Non-Woven Mat

COMMOM FABRICATION METHODS

• Vacuum Bag - Autoclave Molding• Compression Molding• Filament Winding• Resin Transfer Molding• Pultrusion• Thermoforming

Tape Lay-Up Machine

Autoclave

Molded Radio Box

Automotive Gas Tank Heat Shield

•25% E-glass

•PET RBR Flake

Filament Winding Machine

Resin Transfer Molding (RTM)– Closed mold process, reduced volatile emissions– Near net-shape molded parts – Close dimensional tolerances– Smooth surface finish on both sides of part– Cores, ribs and inserts can be encapsulated into part– Requires expensive matched metal heated tools

Rigid Metal Mold

Fiber PreformResin

Resin Injection Pot

Piston

Rigid Base

Rigid Lid Air Port

Rigid Metal Mold

Fiber PreformResin

Resin Injection Pot

Piston

Rigid Base

Rigid Lid Air Port

Textile Material Forms

Textile Material Forms

F-22 Raptor Program

• Sine-Wave Spar Panel• 20 % reduction in manufacturing cost

Vacuum Assisted Resin Transfer Molding (VARTM)

– Upper half of metal mold replaced by vacuum bag.– Atmospheric pressure provides both the resin driving

force and the preform compaction force.– Distribution medium is used to facilitate the resin flow

(SCRIMP®).– Room temperature process.

Wind Turbine Blade

Contest 55 Sailing Yacht• Hull Dimensions

−

16.4 m long−

4.5 m wide−

2.5 m high

http://www.polyworx.com

Pultrusion Process

Pultrusion Machine

Pultrusion Machine

Pultruded ProductsPultruded Rod Pultruded Structural Shapes

Pultruded Products

Composite Building Panel System Handrail Systems

Thermoforming Process

Thermoformed Composite Parts