Vacuum Bag Molding

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This manufacturing process is designed to improve the mechanical properties of laminate (two or more layers of fiber reinforcement bonded with a resin). A vacuum is created to force out trapped air and excess resin, compacting the laminate. High-fiber concentration provides better adhesion (between layers of sandwich construction). In addition, vacuum bag molding helps eliminate excess resin that builds up when structures are made using (open-molding) hand lay-up techniques.

VACUUM BAG MOLDING improves the mechanical properties of open-mold laminates. This process can produce laminates with a uniform degree of consolidation, while at the same time removing entrapped air, thus reducing the finished void content. By reducing the pressure inside the vacuum bag, external atmospheric pressure exerts force on the bag. The pressure on the laminate removes entrapped air, excess resin, and compacts the laminate, resulting in a higher percentage of fiber reinforcement.

Vacuum bagging can be used with wet-lay laminates and prepreg advanced composites. In wet lay up bagging the reinforcement is saturated using hand lay up, then the vacuum bag is mounted on the mold and used to compact the laminate and remove air voids. In the case of pre-impregnated advanced composites molding, the prepreg material is laid up on the mold, the vacuum bag is mounted and the mold is heated or the mold is placed in an autoclave that applies both heat and external pressure, adding to the force of atmospheric pressure. The prepreg-vacuum bag-autoclave method is most often used to create advanced composite aircraft and military products.

Structures fabricated with traditional hand lay up techniques can become resin rich and vacuum bagging can eliminate the problem. Additionally, complete fiber wet-out can be accomplished if the process is done correctly. Improved core bonding is also possible with vacuum bag processing.


Process:
In the simplest form of vacuum bagging, a flexible film (PVA, nylon, mylar, or polyethylene) is placed over the wet lay up, the edges are sealed, and a vacuum is drawn. A more advanced form of vacuum bagging places a release film over the laminate, followed by a bleeder ply of fiberglass cloth, non-woven nylon, polyester cloth, or other material that absorbs excess resin from the laminate. A breather ply of a non woven fabric is placed over the bleeder ply, and the vacuum bag is mounted over the entire assembly. Pulling a vacuum from within the bag uses atmospheric pressure to eliminate voids and force excess resin from the laminate. The addition of pressure further results in high fiber concentration and provides better adhesion between layers of sandwich construction. When laying non-contoured sheets of PVC foam of balsa into a female mold, vacuum bagging is the technique of choice to ensure proper secondary bonding of the core to the outer laminate.


Molds:
Molds are similar to those used for conventional open mold processes.