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