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  • Introduction to Composites
    • Fundamentals of composite materials
      • How Composites Differ From Metals
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    • Systems approach to composite materials
  • Foundational Knowledge
    • Materials science
      • Material structure
        • Polymer (matrix) structure
          • Thermoplastic polymers
          • Thermoset polymers
      • Material properties
        • Basic Definitions of Material Properties
          • Thermal conductivity
          • Specific heat capacity
          • Thermal diffusivity
        • Polymer properties
          • Heat of reaction
          • Degree of cure
          • Outgassing of Polymer Resins
          • Glass transition temperature (Tg)
          • Viscosity (resin)
        • Reinforcement properties
        • Composite properties
          • Fatigue Limits
          • Failure Theories
          • Safety Factors
          • Macro-Mechanics
          • Micro-Mechanics
    • Processing science
      • Thermal behaviour
        • Heat transfer
          • Conduction
          • Convection
        • Thermal phase transitions of polymers
        • Cure of thermosetting polymers
    • Foundational method documents
      • How to measure curing time and degree of cure
      • How to measure gel time
      • How to measure reinforcement content (and corresponding matrix content)
      • Tensile Testing
  • Systems Knowledge
    • System parameters - inputs and outcomes
    • System interactions
    • Thermal and cure/crystallization management (TM)
      • Effect of material in a thermal management system
      • Effect of shape in a thermal management system
      • Effect of tooling in a thermal management system
      • Effect of equipment in a thermal management system
    • Materials deposition and consolidation management (MDCM)
    • Residual stress and dimensional control management (RSDM)
      • Effect of material in a RSDM system
      • Effect of shape in a RSDM system
      • Effect of tooling in a RSDM system
      • Effect of equipment in a RSDM system
    • Machining and assembly management (MAM)
    • Quality/inspection management (QIM)
    • Systems knowledge method documents
      • How to perform an experimental thermal profile
  • Systems Catalogue
    • The factory
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      • Objects in the factory (what)
        • Material
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            • Honeycomb
          • Prepreg
          • Matrix
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            • Polyester resin
        • Shape
        • Tooling and consumables
        • Equipment
          • Autoclave
          • Hot press
          • Oven
          • Room temperature transformation
      • Factory cells (where and how)
        • Testing
          • Thermomechanical Analyzer (TMA)
        • Material deposition
          • Automated fibre placement (AFP)
          • Compression moulding
          • Hand layup prepreg (Autoclave/Out-of-autoclave) processing
          • Vacuum assisted resin transfer moulding (VARTM)/resin infusion (VARI)
          • Wet layup
        • Thermal transformation
    • Resources
      • Composites Courses at Canadian HEI
  • Practice
    • Integrated Product Development
      • Practice for Developing a Product
        • Composite Production Part Drawing
        • Selecting Functional Requirements
        • Shape Development
        • Material Selection
        • Practice for Identifying Process Steps
      • Practice for Developing a Process Step
        • Practice for Developing a Deposition Step
          • Resin degassing
        • Practice for Developing a Demoulding Step
        • Practice for Developing a Consolidation Step
          • Debulking
          • Vacuum Bagging
            • Vacuum Bagging for Vacuum Infusion
            • Vacuum Bagging for Prepregs
          • Consolidation of Thermoplastics
        • Practice for Developing a Receiving and Storage Step
        • Practice for developing a thermal transformation process step
          • Developing production scale tooling
      • Ensuring quality during curing of thick parts
      • Ensuring tooling choice meets part quality metrics
      • Ensuring quality during production of variable thickness parts
      • Maintaining equivalency during cure for different fibre architectures
    • Production Optimization
      • Process selection for production scale-up
      • Decreasing Cure Cycle Time
      • Increasing throughput by curing parts simultaneously
      • Maintaining quality when scaling-up from coupons to production-ready parts
      • Optimizing a cure cycle for improved production rates
    • Production Troubleshooting
      • Practice for troubleshooting a Light RTM step
      • Ensuring appropriate resin flow and part consolidation for a new cure cycle
      • Troubleshooting scaling-up issues from coupons to parts
      • Ensuring appropriate resin flow and part consolidation for a new material
      • Troubleshooting quality issues during cure for different equipment types
      • Transitioning tooling styles between different thermal transformation equipment
      • Troubleshooting scaling issues from small to large parts
      • Troubleshooting when changing production tooling material
      • Troubleshooting a cure cycle for improved production rates
      • Maintaining part quality when changing curing equipment
      • Troubleshooting tooling to achieve part quality
      • Troubleshooting part quality during cure when changing the reinforcement
      • Troubleshooting scale-up issues from thin to thick parts
  • Case Studies
    • Development
      • Lack of Requirements in Product Development
      • Conducting a thermal tooling survey on three complex tools of different materials
      • Developing for Future Production Scale Up
      • Use of Right Sized Simulation to Aid Decision Making in Thermoplastic Composite Manufacturing Systems
      • Feasibility of Using Composite Materials in Mobile Food Truck Tandoor Ovens
      • Process Selection for a Composite Transit Vehicle Door
      • Automotive Battery Enclosure Material and Manufacturing Assessment
      • Product Development Stage Gate Methodology for a Composite Shroud
    • Optimization
      • Optimization of a hot press process for bike components
      • Optimizing Cost vs Weight for Low Production Volume Parts
      • Cost Comparison Study of a GFRP Leisure Boat Hull Manufacturing Method; Spray Up vs Resin Infusion
      • Using Barcol Hardness Measurements to Correlate Hardness and Degree of Cure
    • Troubleshooting
      • Troubleshooting of room temperature processes for large recreational and industrial parts
  • Perspectives
    • Presentations
      • Dr. Anoush Poursartip's cdmHUB global composites expert webinar
    • Interviews
      • Interview with Prof. Kevin Potter
    • AIM Events - Webinars
      • Advanced x-ray imaging of carbon fiber microstructure
      • Implementation of Bolted Joints in Composites
      • Filament Winding
      • Introduction to Bolted Joints in Composites
      • Introduction to Damage and Repair of Composite Sandwich Structures
      • Introduction to Non-Destructive Testing of Composite Materials
      • Introduction to Repair of Composite Structures
      • Viscoelasticity and Composite Materials
      • Introduction to Adhesive Bonding - Part II
      • Introduction to Adhesive Bonding - Part I
      • Sandwich Panels in Aerospace
      • Introduction to Tooling for Composite Materials Processing
      • An Introduction to Composites Sustainability
      • Porosity in Composite Materials - Part II
      • Porosity in Composite Materials - Part I
      • Pultrusion of Thermoplastic Composites
      • Simulation models for rapid liquid composite molding
      • CKN’s Approach to Developing Products with Composite Materials
      • Introduction to Sandwich Structures - Materials and Processing
      • Case Study: Optimizing a Press Moulding Process
      • Introduction to the welding of thermoplastic composites
      • Introduction to the processing of thermoplastic composites
      • Heat Transfer in Composites Processing
      • Effect of cure on mechanical properties of a composite (Part 2 of 2)
      • Effect of cure on mechanical properties of a composite (Part 1 of 2)
      • Fabric Forming: how it affects design and processing, and how simulation can address this
      • Fibre Architecture: Availability, pros and cons, and selection for my application
      • Strengthening the Canadian Advanced Manufacturing Innovation Ecosystem: What types of intellectual property matter, and to whom?
      • Understanding Polyester Resin Processing: The Effect of Ambient Temperature on the Final Part
      • Composites Process Simulation: A Review of the State of the Art for Product Development
      • Resin Behaviour During Processing: What are the key resin properties to consider when developing a manufacturing process?
      • The Composites Knowledge in Practice Centre – an open resource for composites manufacturing knowledge and best practices
      • Deconstructing composites ''processing'' - Why it seems so complex and how to think about it in a structured way
      • Parameters for Structural Analysis of Composites
      • Costing composite parts
      • Composite materials engineering webinar series
        • Composite materials engineering webinar session 1 - Introduction
        • Composite materials engineering webinar session 2 - Constituent Materials - Fiber
        • Composite materials engineering webinar session 3 - Constituent materials - Resin
        • Composite materials engineering webinar session 4 - Thermal management and resin cure
        • Composite materials engineering webinar session 5 - Manufacturing processes - Introduction
        • Composite materials engineering webinar session 6 - Manufacturing processes - Prepreg processing
        • Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding
        • Composite materials engineering webinar session 8 - Mechanics of composites - Part 1: Lamina level
        • Composite materials engineering webinar session 9 - Mechanics of composites - Part 2: Laminate level
        • Composite materials engineering webinar session 10 - Failure of composites
        • Composite materials engineering webinar session 11 - Defects
        • Composite materials engineering webinar session 12 - Testing
    • Diversity & Inclusion Coffee Breaks
      • D&I with Janice Barton
      • D&I featuring Kero Saleib
      • D&I featuring Rosemary Pham
      • D&I featuring Sampada Bodkhe
      • D&I featuring Isabelle Paris
      • D&I featuring Janic Lauzon
      • D&I featuring Anoush Poursartip
      • D&I featuring Courtney Mandock

Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding - A126

From CKN Knowledge in Practice Centre
Perspectives - A8AIM Events - Webinars - A115Composite materials engineering webinar series - A119Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding - A126
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Composite materials engineering webinar session 7 - Manufacturing processes - Liquid composite moulding
Perspectives article
A126 Video Thumbnail Image-HsmT8sFXNyd5.jpg
Document Type Article
Document Identifier 126
Themes
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Webinar Date
  • August 5, 2020

Introduction[edit | edit source]

Liquid composite moulding is a family of processes that involve saturating dry fiber reinforcement with liquid resin using a pressure differential in the mould. Common processes include Vacuum assisted resin transfer molding (VARTM)/resin infusion (VARI), Resin transfer molding (RTM), Reaction injection molding (RIM) and Light resin transfer molding (Light RTM). These process can be categorized based on whether the mold is closed or single sided; and the driving force for the resin deposition.

Positive pressure Vacuum Positive pressure + vacuum
Closed mold N/A
Single sided mold N/A Vacuum assisted resin transfer molding (VARTM)/resin infusion (VARI) N/A

This session lays out the fundamental differences in the aforementioned processes, and when and where each process is applicable. Resin flow theory based on Darcy’s law is then introduced as well as a procedure for process design.

Webinar[edit | edit source]

Webinar slides[edit | edit source]

Webinar slides available by clicking on the icon below

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Additional information for select chapters[edit | edit source]

Chapter Chapter Title Links to related information in the Knowledge in Practice Centre
1 Welcome & introductions N/A
2 Overview of Webinar Series
3 Introduction: Liquid Composite Moulding Future content
4 Important concept: Vacuum Future content
5 Important concept: Preform Future content
6 Important concept: Permeability Future content
7 Important concept: Fibre bed compaction Future content
8 Important concept: Resin properties
9 Important concept: Flow front Future content
10 Important concept: Racetracking Future content
11 Important concept: Dry-spots Future content
12 Important concept: 2D and 3D flow Future content
13 Important concept: Micro and macroscopic flow Future content
14 Important concept: Fibre washout Future content
15 Flow Theory (Darcy's law) Future content
16 Derivation: Fill time (linear; constant pressure) Future content
17 Position of flow front as a function of time Future content
18 Different types of flow and boundary conditions Future content
19 Equations for all types of flow Future content
20 Overview: Liquid composite moulding processes Future content
21 Intro to the vacuum infusion process (VIP) Future content
22 Issues to watch out for with vacuum infusion Future content
23 Applications of the vacuum infusion process Future content
24 Case study: Radio telescope dish manufacturing N/A
25 Intro to resin transfer moulding (RTM) Future content
26 Issues to watch out for with RTM Future content
27 Applications of RTM Future content
28 Intro to light resin transfer moulding (LRTM) Future content
29 Issues to watch out for with LRTM Future content
30 Applications of LRTM Future content
31 Case study: Thermal management during VIP Future content
32 Wrap-up N/A
33 Q&A N/A


Related pages

Page type Links
Introduction to Composites Articles
Foundational Knowledge Articles
Foundational Knowledge Method Documents
Foundational Knowledge Worked Examples
Systems Knowledge Articles
Systems Knowledge Method Documents
Systems Knowledge Worked Examples
Systems Catalogue Articles
Systems Catalogue Objects – Material
Systems Catalogue Objects – Shape
Systems Catalogue Objects – Tooling and consumables
Systems Catalogue Objects – Equipment
Practice Documents
Case Studies
Perspectives Articles



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Engineered materials (designed to have specific properties) made from two or more constituent materials with different physical or chemical properties. The constituents remain separate and distinct on a macroscopic level within the finished structure.

For polymer matrix composites (PMCs), resin refers to the matrix; the continuous material phase that binds the reinforcement together, maintains shape, and transfers load. Resins are divided into two main groups: thermosets and thermoplastics.

Resin flow in between fibre tows.

Flow front refers to the leading edge of the resin as it is flowing into and through the fibre preform.

Vacuum Infusion Process (VIP) involves placing a preform on a one sided tool, sealing a vacuum bag on top of it, and drawing resin through the preform with vacuum.

Vacuum Infusion Process (VIP) - also known as vacuum assisted resin infusion (VARI), vacuum assisted resin transfer moulding (VARTM) or often just resin infusion. VIP is a liquid composite moulding (LCM) closed mould process with a single side tool and vacuum bag where the resin is drawn through the preform using vacuum.

Resin transfer moulding (RTM) involves loading a preform into a two (or more) piece, matched tool, closing it, and injecting resin under pressure (~15-100 psi, or ~1-7 bar).

Well suited to small to medium sized parts, limited to large sizes due to injection pressure loads and tool cost.

Light Resin Transfer Moulding (LRTM) uses a semi rigid tool half (A side) that is similar to those used in VIP and a semi flexible tool half (B side) (typically made of thin fibreglass).

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Welcome

Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:

Understanding Composites Processing

The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:

The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.

The relationship between material, shape, tooling & consumables and equipment during a process step


Interrelationship of Function, Shape, Material & Process

Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:

The relationship between function, material, shape and process


Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.

The relationship between function, material, shape and process consisting of Equipment and Tooling and consumables


Workflows

The KPC's Practice and Case Study volumes consist of three types of workflows:

  • Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
  • Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
  • Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.
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