Optimizing Towpreg Parameters for Filament Winding: A Comparison With Wet Winding

ABSTRACT This study investigates the impact of replacing traditional wet filament winding with tacky towpreg winding. A novel aspect of this work is the precise exploration of the relationship between the precuring percentage of towpregs (10%, 15%, and 20%) and their physical state (wet, tacky, or dry), as well as the winding process and the resulting composite quality. Additionally, a suitable commercial resin system for filament winding, alongside a one‐component blend, was used to compare with the wet winding process. Comprehensive evaluations, including viscometry, impregnation, winding, and mechanical property assessments, were conducted to optimize the resin formulation and impregnation temperature. Results demonstrate significant improvements in mechanical properties for towpreg composites, with tensile strength in the fiber direction, transverse tensile strength, and interlaminar shear strength increased by 12%, 45%, and 47%, respectively, compared to wet‐wound samples. Additionally, cross‐sectional imaging revealed a substantial reduction in void content, from 6% in wet winding to just 2% in towpreg winding. This study highlights the innovative potential of tacky towpregs with a certain degree of precure in filament winding, offering enhanced mechanical performance and reduced void content while providing critical insights into the role of precuring in optimizing composite quality.