High performance yachts utilise a large amount of Carbon Fibre Reinforced Plastics (CFRP) in masts, booms, hulls, decks, etc. The commonly applied manufacturing method is consolidation (applied pressure at raised temperatures) of fibre reinforcements pre-impregnated with thermoset polymer resins (a.k.a. Prepreg). Prepreg composites are typically processed within large pressurised ovens (autoclaves), after the time consuming and mostly manual process of laminate layup. This project will explore the significant cost savings (labour and material costs) available through application of a significantly different manufacturing process; Resin Infusion. In this process the fibrous reinforcing structure (or preform) is first laid up in the mould. The preform is then contained under a vacuum bag, placed under vacuum, and subsequently infused with a liquid epoxy resin. Building from a 2017 project that developed an infusion process for flat CFRP panels, this project is focussed on development and analysis of the key step required to manufacture complex part geometries. The layup of a stable and robust 3D preform (or preforming) requires a “binder” material to adhere 2D fibre reinforcement layers together, prior to vacuum bagging and infusion with resin. A review will be made of approaches taken to binder/preforming in industry, and viable processing routes for the industrial partner developed. The influence of the volume content and positioning of the binder on resin flow, and on the final mechanical properties of the laminate, will also be studied. Southern Spars is the industrial partner for this project, being one of the main collaborators in a large NZ funded research programme running at the CACM.
Undergraduate
This project will generate one or two feasible binder based preforming techniques for the industrial partner. These techniques will be demonstrated on example tool geometries (both flat and 3D), with the influence of the binder on flow and laminate structural performance studied via a parametric study. Student participants will gain knowledge on manufacture of composite structures, with a strong focus on the preforming and resin infusion, and will have the opportunity to work with staff at Southern Spars.
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CACM - Strength of Materials Lab (Newmarket 902 Lvl 3, Lab)