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Controlled Preform Consolidation for Manufacturing Difficult Resin System Composites

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Abstract:

Novel multifunctional resins and composites present multiple manufacturing challenges that need to be overcome to allow for wider adoption. These challenges include high viscosity, short cure windows, low permeability preforms, and non-standard cure kinetics. Standard liquid composite molding methods (such as resin infusion under flexible tooling [RIFT], resin transfer molding [RTM], or compaction-RTM) are poorly equipped to manufacture these new materials. A new system is presented that combines the abilities of RIFT/RTM/c-RTM while introducing controlled deformation of the preform during infusion to remove flow through the preform. This manufacturing method allows the preform to lie uncompacted, while still under vacuum, during infusion which allows resin to flow unrestricted between plies. Then once infusion has occurred, compaction proceeds to produce the final composite geometry. This method has been successfully implemented to manufacture structural power devices with a biphasic resin system and metal coated carbon aerogel preform, as well as a vitrimer composite with a high-viscosity/short-cure resin thought high weight carbon fiber preform. The novel and flexible manufacturing parameters of this new system present a low-cost route towards optimizing the manufacture of challenging and novel resin systems, allowing for a faster understanding and implementation of these materials.

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Periodical:

Solid State Phenomena (Volume 387)

Pages:

75-84

DOI:

https://doi.org/10.4028/p-eB7jZs

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Cite this paper

Online since:

April 2026

Authors:

Dominic R. Palubiski*, Natasha Shirshova, Emile S. Greenhalgh, Milo S. P. Shaffer, Dmitry S. Ivanov

Keywords:

In Situ Preform Deformation, Liquid Composite Molding, Multifunctional Resin Systems

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Creative Commons CC BY 4.0

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* - Corresponding Author

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