Production Processes

Composite materials are manufactured by two main assembly approaches.

Molding and curing of composite material are exposed to free air. Cheap and practical.

Molding and curing of composite material are inside a closed cavity without atmospheric exposure. Excellent quality.

To maximize the stiffness, strength, and overall “quality” of the composite material/part, the manufacturer should practice the following guideline:

Select the right combination of reinforcements, matrix, and additives

Maintain fiber volume fraction at around 50~65% (optimum fiber volume fraction depends on design)

Achieve uniform fiber volume fraction throughout part (e.g., avoid resin-rich or resin-starved regions)

Eliminate void content (e.g., eliminate air bubbles)

Ensure good adhesive bonding between fiber/matrix, between plies, and from part-to-part

Eliminate all contaminants

Build a functional supply chain by working with reliable vendors

Most composites are still fabricated manually. So guide, train, and protect the employees well