Double diaphragm compression moulding, comparing thermoset prepreg with dry fabric and liquid resin

Double diaphragm compression moulding (DDCM) is a recently developed process for forming and curing epoxy/carbon prepreg materials. In this study, the process has been used to compare the use of a prepreg with a dry fabric/liquid resin. Mechanical testing demonstrated equivalent mechanical properties were produced using the two approaches. A complex geometry demonstrator component was successfully manufactured with both material types. Finite Element modelling of the forming process successfully replicated diaphragm wrinkles seen in the practical trials. This initial study has successfully demonstrated the use of a dry fabric/liquid resin as an alternative to prepreg when used with the DDCM process, opening up further options for low cost, high rate manufacture of complex geometry composite components.