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Optimizing Bladder Resin Transfer Molding Process to Manufacture Complex, Thin-Ply Thermoplastic Tubular Composite

Somen K Bhudolia1, Pavel Perrotey2, Goram Gohel1

  • 1School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798, Singapore.

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|December 10, 2021
PubMed
Summary

This study optimizes Bladder-Assisted Resin Transfer Molding (B-RTM) for thin-ply, non-crimp fabrics (NCFs). We detail the successful injection of complex thermoplastic structures, addressing manufacturing challenges for mass production.

Keywords:
consolidationnon-crimp fabricsresin transfer moldingthermoplastic resin

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Area of Science:

  • Materials Science
  • Manufacturing Engineering

Background:

  • Bladder molding, especially with prepregs, is common in sports.
  • Bladder-Assisted Resin Transfer Molding (B-RTM) offers automation potential for complex hollow composites.
  • Thin-ply, non-crimp fabrics (NCFs) enhance mechanical properties and reduce weight but pose injection challenges.

Purpose of the Study:

  • To experimentally investigate the injection of low-permeability, thin-ply, complex thermoplastic tubular structures using B-RTM.
  • To optimize process parameters for reduced injection time and improved consolidation.
  • To identify and address manufacturing challenges associated with this process.

Main Methods:

  • Experimental case study focusing on Bladder-Assisted Resin Transfer Molding (B-RTM).
  • Utilized thin-ply, non-crimp fabrics (NCFs) in a complex thermoplastic tubular structure.
  • Systematic analysis of process parameters and boundary conditions.

Main Results:

  • Successfully demonstrated the injection of a challenging low-permeability, thin-ply composite structure.
  • Identified key process parameters influencing injection time and consolidation.
  • Documented manufacturing challenges and proposed practical solutions.

Conclusions:

  • B-RTM is a viable method for mass-producing complex hollow thermoplastic composites with NCFs.
  • Process optimization is crucial for overcoming injection difficulties and achieving high-quality parts.
  • This research provides a foundational case study for future advancements in automated composite manufacturing.