CHAPTER - 3

COMPOSITE MANUFACTURING
3.1 INTRODUCTION
3.2 MOULDING PROCESS FOR POLYMER MATRIX COMPOSITES
3.3 CLASSIFICATION OF MANUFACTURING PROCESSES
3.3.1 Open Mold Po!e""
3.3.2 Clo"ed Mold Po!e""
3.3.3 Con#$n%o%" Po!e""
3.&.1 Sp'( L'(-%p
3.&.2 H'nd L'(-%p) *e# L'(-%p
3.&.3 F$l'+en# *$nd$n,
3.&.& S-ee# Mold$n, Co+po%nd
3.&.. E/p'n"$on #ool +o%ld$n,
3.&.0 Con#'!# Mold$n,
3.. CLOSED MOLD PROCESSES
3...1 Co+pe""$on Mold$n,
3...2 1'!%%+ 2', Mold$n,
3...3 E/pend'3le 1'!%%+ 2',,$n,
3...& Re%"'3le 1'!%%+ 2',,$n,
3.... A%#o!l'4e Mold$n,
3...0 In5e!#$on Mold$n,
3...6 Re"$n T'n"7e Mold$n, 8RTM9
3...: 1'!%%+ A""$"#ed Re"$n T'n"7e Mold$n, 81ARTM9
3...; Re"$n F$l+ In7%"$on 8RFI9
3.0 CONTINUOUS PROCESSES
3.0.1 P%l#%"$on
3.0.2 2'$d$n,
3.0.3 Pepe, Mold$n,
3.2.1 M'#!-ed-d$e Mo%ld Me#-od"
3.2.2 Con#'!# Mo%ld Me#-od"
3.2.3 F$l'+en# *$nd$n,
3.2.& P%l#%"$on

3.1 INTRODUCTION
Manufacturing is a very broad discipline and encompasses several processes such
as fabrication, machining and joining. The fabrication methodology of a composite part
depends mainly on three factors: (i) the characteristics of constituent matrices and
reinforcements, (ii) the shapes, sizes and engineering details of products and (iii) end
uses. The composite products are too many and cover a very ide domain of applications
ranging from an engine valve, or a printed circuit board laminate, or a large-size boat hull
or to an aircraft ing. The fabrication techni!ue varies from one product to the other. The
matri" types (i.e., hether they are plastics, metals or ceramics) play a dominant role in
the selection of a fabrication process. #imilar process cannot be adapted to fabricate an
engine blade made ith fibre reinforced plastics and metal matri" composites. The
process parameters may also have to be modified, even hen one uses the same matri"
type, but to different matrices. $or e"ample, the processing ith phenolics re!uires
additional heating, hereas epo"ies can be processed under ambient conditions.
%articulate reinforcements and short fibres are mi"ed ith resin to produce either bul&
moulding composite compounds ('M(s) or sheet moulding composite compounds
(#M(s) hich are then used as base materials to fabricate composite parts. )ne method