Automated Process Based on Functionalized Preform and Net-shape High Performance Resin Transfer Molding for High Volume Structural Applications

In this paper, a new process is highlighted for mass production of composite structural parts for the automotive and high-volume aerospace markets. This process follows different steps: (1) Simulation of the process to optimize the design of the 3D part and its corresponding 2D blank, (2) High speed Automated Fiber Placement (AFP) of 2D tailored dry preform blanks made from direct fiber, online fiber spreading and binder application, (3) Preform functionalization to improve its formability and permeability, but also to make handling and trimming easier, (4) Forming of the 2D functionalized preform to 3D shape and net shape trimming, (5) Net shape preform impregnation with High-Pressure-Resin-Transfer-Molding (HP-RTM), thanks to excellent through thickness (z direction) permeability, and preform stability. To assess the process performance and resulting parts, 3D parts and 2D coupons were manufactured using the new developed preforms and Non-Crimp-Fabric (NCF), having in both cases the same fiber and matrix. The performances were evaluated all along the process steps and the results show improvements in several key process parameters, equivalent mechanical performances and increase surface quality, hence resulting in less effort for surface preparation.