Assignment

Submitted By
Sami Ullah

Submitted To
Dr. Karamat

Reg. No.
F22BCHEM3M02025

Course
Composite Material & Analytical Applications
(CHEM-31204)

Topic
Manufacturing Methods of Composite Material

Date
9-03-2023

M.Phil. Analytical Chemistry

The Islamia university of Bahawalpur

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What is composite material?
A composite material is a combination of two materials with different physical and chemical
properties. When they are combined they create a material which is specialized to do a certain
job, for instance to become stronger, lighter or resistant to electricity. They can also improve
strength and stiffness. The reason for their use over traditional materials is because they improve
the properties of their base materials and are applicable in many situations.

Manufacturing Methods of composite Material

There are three types of composite manufacturing processes:
1. Open molding
2. Closed molding
3. Cast polymer molding
There are a variety of processing methods within these molding categories, each with its own
benefits.

 Open Molding
In open molding, raw materials (resins and fiber reinforcements) are exposed to air as they cure
or harden. Open molding utilizes different processes, including hand lay-up, spray-up, casting,
and filament winding.

1. Hand Lay-Up:
Hand lay-up is the most common and least expensive open-molding method because it requires
the least amount of equipment. Fiber reinforcements are placed by hand in a mold and resin is
applied with a brush or roller. This process is used to make both large and small items, including
boats, storage tanks, tubs and showers.
Hand lay-up is an open molding method suitable for making a wide variety of composites
products from very small to very large. Production volume per mold is low; however, it is feasible
to produce substantial production quantities using
multiple molds. Hand lay-up is the simplest
composites molding method, offering low cost
tooling, simple processing, and a wide range of part
sizes. Design changes are readily made. There is a
minimum investment in equipment. With skilled
operators, good production rates and consistent
quality are obtainable.

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Process:
Gel coat is first applied to the mold using a spray gun for a high quality surface. When the gel
coat has cured sufficiently, roll stock fiberglass reinforcement is manually placed on the mold.
The laminating resin is applied by pouring, brushing, spraying, or using a paint roller. FRP rollers,
paint rollers, or squeegees are used to consolidate the laminate, thoroughly wetting the
reinforcement and removing entrapped air. Subsequent layers of fiberglass reinforcement are
added to build laminate thickness. Low density core materials such as end-grain balsa, foam, and
honeycomb, are commonly used to stiffen the laminate. This is known as sandwich construction.
Molds:
Simple, single cavity molds of fiberglass composites construction are generally used. Molds can
range from small to very large and are low cost in the spectrum of composites molds.

2. Spray-Up:
Spray-up, or chopping, is an open mold method similar to hand lay-up in its suitability for making
boats, tanks, transportation components, and tub/shower units in a large variety of shapes and
sizes. A chopped laminate has good conformability and is sometimes faster to produce than a
part made with hand lay-up when molding complex shapes.
In the spray-up process, the operator controls thickness and consistency, therefore the process
is more operator dependent than hand lay-up. Although production volume per mold is low, it is
feasible to produce substantial production quantities using multiple molds. This process uses
simple, low cost tooling and simple processing. Portable equipment permits on-site fabrication
with virtually no part size limitations. The process may be automated.
Process:
As with hand lay-up, gel coat is first applied to the mold and allowed to cure. Continuous strand
glass roving and initiated resin are then fed through a chopper gun, which deposits the resin-
saturated “chop” on the mold. The laminate is
then rolled to thoroughly saturate the glass
strands and compact the chop. Additional layers
of chop laminate are added as required for
thickness. Roll stock reinforcements, such as
woven roving or knitted fabrics, can be used in
conjunction with the chopped laminates. Core
materials of the same variety as used in hand lay-
up are easily incorporated.

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Molds:
These are the same molds as hand lay-up: simple, single cavity molds of fiberglass composites
construction. Molds can range from small to very large and are low cost in the spectrum of
composites molds.

3. Filament Winding:
Filament winding is an automated open molding process that uses a rotating mandrel as the
mold. The male mold configuration produces a finished inner surface and a laminate surface on
the outside diameter of the product.
Filament winding results in a high degree of fiber loading, which provides high tensile strength in
the manufacture of hollow, generally cylindrical products such as chemical and fuel storage tanks,
pipes, stacks, pressure vessels, and rocket motor cases. The process makes high strength-to-
weight ratio laminates and provides a high degree of
control over uniformity and fiber orientation. The
filament winding process can be used to make
structures that are highly engineered and meet strict
tolerances. Because filament winding is computer-
controlled and automated, the labor factor for
filament winding is lower than other open molding
processes.
Process:
Continuous strand roving is fed through a resin bath and wound onto a rotating mandrel. The
roving feed runs on a trolley that travels the length of the mandrel. The filament is laid down in
a predetermined geometric pattern to provide maximum strength in the directions required.
When sufficient layers have been applied, the laminate is cured on the mandrel. The molded part
is then stripped from the mandrel. Equipment is available for filament winding on a continuous
basis with to axis winding for pressure cylinders. Filament winding can be combined with the
chopping process and is known as the hoop chop process.
Molds:
Filament winding uses mandrels of suitable size and shape, made of steel or aluminum, to form
the inner surface of the hollow part. Some mandrels are collapsible to facilitate part removal.

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  Closed Molding:
In closed-molding, raw materials (fibers and resin) cure inside a two-sided mold or within a
vacuum bag (shut off from air). Closed-molding processes are usually automated and require
special equipment, so they’re mainly used in large plants that produce huge volumes of
material—up to 500,000 parts a year.

1. Vacuum Bag Molding:

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 prepare advanced composites. In wet
layup bagging the reinforcement is saturated using hand layup, 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 prepare 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 prepared-
vacuum bag-autoclave method is most often used to
create advanced composite aircraft and military
products. Structures fabricated with traditional
hand layup 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 layup, 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

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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.

2. Vacuum Infusion Processing:

Vacuum infusion processing is a variation of vacuum bagging in which the resin is introduced into
the mold after the vacuum has pulled the bag down and compacted the laminate.
Vacuum infusion can produce laminates with a uniform degree of consolidation, producing high
strength, lightweight structures. This process uses the same low-cost tooling as open molding
and requires minimal equipment. Vacuum infusion offers substantial emissions reduction
compared to either open molding or wet lay-up vacuum bagging.
The method is defined as having lower than atmospheric pressure in the mold cavity. The
reinforcement and core materials are laid-up dry in the mold by hand, providing the opportunity
to precisely position the reinforcement. When
the resin is pulled into the mold the laminate
is already compacted; therefore, there is no
room for excess resin. Vacuum infusion
enables very high resin-to-glass ratios and the
mechanical properties of the laminate are
superior. Vacuum infusion is suitable to mold
very large structures and is considered a low-
volume molding process.
Process:
The mold may be gel coated in the traditional fashion. After the gel coat cures, the dry
reinforcement is positioned in the mold. This includes all the plies of the laminate and core
material if required. A perforated release film is placed over the dry reinforcement. Next a flow
media consisting of a coarse mesh or a “crinkle” ply is positioned, and perforated tubing is
positioned as a manifold to distribute resin across the laminate. The vacuum bag is then
positioned and sealed at the mold perimeter. A tube is connected between the vacuum bag and
the resin container. A vacuum is applied to consolidate the laminate and the resin is pulled into
the mold.
Molds:
Molds are similar to those used for conventional open-mold processes.

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 3. Resin Transfer Molding:
Resin transfer molding (RTM) is an intermediate volume molding process for producing
composites. In RTM, resin is injected under pressure into a mold cavity. This process produces
parts with two finished surfaces.
By laying up reinforcement material dry inside the mold, any combination of material and
orientation can be used, including 3-D reinforcements. Part thickness is determined by the tool
cavity. Fast cycle times can be achieved in temperature-controlled tooling and the process can
range from simple to highly automated. RTM can use a wide variety of tooling, ranging from low-
cost composite molds to temperature controlled metal tooling. Vacuum assist can be used to
enhance resin flow in the mold cavity.
Process:
The mold is gel coated conventionally, if
required. The reinforcement (and core material)
is positioned in the mold and the mold is closed
and clamped. The resin is injected under
pressure, using mix/meter injection equipment,
and the part is cured in the mold. The
reinforcement can be either a preform or a
pattern cut roll stock material. A preform is a
reinforcement that is formed to a specific shape in a separate process and can be quickly
positioned in the mold. RTM can be done at room temperature; however, heated molds are
required to achieve fast cycle times and product consistency. Clamping can be accomplished with
perimeter clamping or press clamping.
Molds:
RTM can utilize either hard or soft tooling depending upon the expected duration of the run. Soft
tooling would be either polyester or epoxy molds, while hard tooling may consist of cast
machined aluminum, electroformed nickel shell, or machined steel molds. RTM can take
advantage of the broadest range of tooling of any composites process. Tooling can range from
very low-cost to high-cost, life-long molds.

4. Compression Molding:
Compression molding is a high-volume, high-pressure method suitable for molding complex,
fiberglass-reinforced polymer parts on a rapid cycle time. There are several types of compression
molding that are defined by the type of material molded: sheet molding compound (SMC), bulk
molding compound (BMC), thick molding compound (TMC), and wet lay-up compression
molding. Compression molding tooling consists of heated metal molds mounted in large

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hydraulic presses. The process can be automated. Compression molding enables part design
flexibility and features such as inserts, ribs, bosses and attachments. Good surface finishes are
obtainable, contributing to lower part finishing cost. Subsequent trimming and machining
operations are minimized in compression molding and labor costs are low.
Process:
The mold set is mounted in a hydraulic or mechanical molding press and the molds are heated
from 250° to 400° F. A weighed charge of molding material is placed in the open mold. The two
halves of the mold are closed and pressure is applied.
Depending on thickness, size, and shape of the part,
curing cycles range from less than a minute to about five
minutes. After cure, the mold is opened and the finished
part is removed. Typical parts include automobile
components, appliance housings and structural
components, furniture, electrical components, and
business machine housings and parts.
Molds:
Tooling usually consists of machined or cast metal or alloy molds that can be in either single or
multiple-cavity configurations. Steel molds are hardened and sometimes chrome plated for
enhanced durability. The molds are heated using steam, hot oil, or electricity. Side cores,
provisions for inserts, and other refinements are often employed. Mold materials include cast of
forged steel, cast iron, and cast aluminum. Matched metal molds can cost 50 times as much as
an FRP open mold and tooling in the $50,000-$500,000 range is not uncommon.

5. Pultrusion:
Pultrusion is a continuous process for the manufacture of products having a constant cross
section, such as rod stock, structural shapes, beams,
channels, pipe, tubing, fishing rods, and golf club shafts.
Pultrusion produces profiles with extremely high fiber
loading; thus, pultruded products have high structural
properties. The process can be readily automated and is
adaptable to both simple and complex cross-sectional
shapes. Very high strengths are possible and labor costs
are low.

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Process:
Continuous strand glass fiber, carbon fiber or basalt fiber roving, mat, cloth, or surfacing veil is
impregnated in a resin bath and then pulled (therefore the term pul-trusion) through a steel die
by a powerful tractor mechanism. The steel die consolidates the saturated reinforcement, sets
the shape of the stock, and controls the fiber/resin ratio. The die is heated to rapidly cure the
resin. Many creels (balls) of roving are positioned on a rack, and a complex series of tensioning
devices and roving guides direct the roving into the die.
Molds:
Hardened steel dies are machined and include a preform area to do the initial shaping of the
resin-saturated roving. The dies include heating which can be electric or hot oil. The latest pul-
trusion technology uses direct injection dies, in which the resin is introduced inside the die, rather
than through an external resin bath.

6. Reinforced Reaction Injection Molding (RRIM):

In the RRIM process, two or more reactive resins are metered and impingement-mixed under
high pressure to form a thermosetting polymer, injected into a mold, and then cured. RRIM
composites have a number of processing advantages including very fast cycle time, low labor,
low mold clamping pressure and low scrap rate. RRIM uses reinforcements to improve the
properties of the resin. With the use of reinforcements, polymerization shrinkage is reduced,
thermal expansion is reduced, droop and sag of the composite at elevated temperatures is
minimized and other key properties such as stiffness, tensile strength and tensile elongation are
generally improved. Milled fibers or flakes can be added directly to the resin before reacting in
the mixing head.
Metering is accomplished with high pressure pumps or injection cylinders. Typically, a small
mixing chamber is used. The two resin streams enter from opposite sides of mix chamber under
high pressure. Mixing occurs from the energy-intensive collision of these two resin streams.
Although the streams are mixed at very high pressure, the result is a low viscosity liquid. The low
viscosity mixed resin is easily injected into the mold at relatively low pressure, 50 psi (345kPa).
Polymerization takes place very quickly within the mold cavity with little or no additional heat
required.
Resins and Reinforcement:
The RRIM process requires special resins and reinforcements. A number of resins, including
epoxies, polyesters, nylons and polyurethanes have been successfully developed for RRIM
processing. Today, polyurethane is the predominate resin in RRIM. Most of the urethanes used
are elastomeric and range in flex modulus from 20,000 psi to well over 500,000 psi (170MPa to

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3.5 GPa). The basic RRIM reinforcements are chopped or hammer milled glass fiber and glass
flake.
Variations on a RRIM theme:
Variations of the RRIM process include structural RIM (SRIM). In this process, chopped fiber
preforms or mats are positioned in the mold cavity. The mold is clamped and resin is injected
into the mold cavity. The reacting resin remains liquid long enough to completely fill the mold
and penetrate the reinforcing fibers. Then the resin quickly cures.
Applications:
Presently, transportation is the principal market for RRIM products. Automotive and truck
applications for RIIM parts include Class A body panels, fascia, bumper beams, spare tire covers,
floor pans and other similar products. The advent of controllable reactivity resins such as
polyuria/amide has introduced a trend toward larger machines, larger clamps and larger parts.
Very large RRIM molded parts weighing over 100 pounds have already been produced.
Breakthrough applications such as this clearly indicate that the future trend in RRIM products will
be toward increased market acceptable featuring larger and more sophisticated parts.

7. Centrifugal Casting:
In centrifugal casting, reinforcements and resin are deposited against the inside surface of a
rotating mold. Centrifugal force holds the materials in place until the part is cured.
With centrifugal casting, the outside surface of the
part, which is cured against the inside surface of the
mold, represents the “finished” surface. The interior
surface of centrifugally cast parts can be given an
additional coating of “neat” or pure resin to improve
surface appearance and provide additional chemical
resistance in the part. Large diameter composite pipe
and tanks are commercially produced by centrifugal
casting.
Advantages of centrifugal casting include a finished exterior surface and containment of volatiles
during processing. The primary limitations of centrifugal casting are the ability to spin molds of
large size and relatively low productivity per tool.

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 8. Continuous Lamination:
Continuous lamination is used to produce composite products such as opaque and translucent
flat or corrugated paneling, truck trailer paneling, refrigerator liners, sanitary paneling, road signs
and other similar products.
Typically, high output machines up to 10 feet (3
meters) wide combine reinforcement and resin on
plastic film that is pulled through the process. A
second plastic film is applied over the
reinforcement and resin to allow mixing and
exclusion of air that is usually accomplished by
compaction rollers.
Cure is completed in an oven. Panels are automatically trimmed to width and cut to length.
Corrugated sheet is produced by forming shoes which hold the compacted sheet in the required
shape during cure. Special surface effects are created by using embossed carrier films that are
later removed. Both mat reinforcements and roving’s chopped by special wide cutters are
employed in the process.
Polyester and acrylic modified polyesters (for improved water resistance) are the primary resins
for continuous lamination.

 Cast Polymers Molding:

Cast polymers are unique in the composites industry: they typically don’t have fiber
reinforcement and are designed to meet specific strength requirements of an application. Cast
polymer molding is used to produce parts of any shape or size.

1. Gel Coated Cultured Stone:

Gel coat is a specialized polyester resin that is formulated to provide a cosmetic outer surface on
a composite product and to provide weather ability for outdoor products.
Several variations of cultured stone products are manufactured using a gel coated surface and a
resin-matrix casting process. In this process a gel coat film (usually clear) is sprayed on the mold
surface. Once the gel coat is sufficiently cured, a polyester resin matrix is blended by adding
various types of fillers to the resin. Pigments for both a solid background color and the look of
veins found in natural stone can be added. The resin matrix is then transferred to the mold, where
vibration is applied to level and compact the matrix. Following the cure, the part is removed from
the mold.
Gel coat is not paint. Paint contains solvents that must evaporate for the paint to dry. The
‘solvent’ in gel coat is styrene monomer and/or methyl methacrylate (acrylic), which cross-links

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during curing. The monomer does not have to leave the system for the gel coat to cure; in fact,
it is beneficial to reduce monomer loss.
The appearance of the cultured stone products is
determined by the type of filler used and by the
application of colorants to the matrix. Fillers come in
a variety of materials. Many of the fillers used in the
composites industry are mineral substances. Mineral
fillers have distinctive shapes that relate to their
chemical structure.
Marble: The natural marble look is reproduced by formulating a matrix using calcium carbonate
filler. In some cases, other fillers or combinations of fillers may be used. Resin, initiator, filler, and
pigment are mixed to form a solid-color matrix. The marble veining effect is created by adding a
second pigment to the matrix and partially mixing it to produce the desired look.
Onyx: The process of manufacturing cultured onyx is similar to that of cultured marble, except
alumina trihydrate (ATH) filler is used. The cultured onyx matrix generally has a higher resin
content compared with cultured marble, and the combination of materials creates a translucent
appearance. Background and veining pigments are added to the matrix to produce an onyx stone
look.
Granite: The cultured granite appearance is created by blending colored chips into the resin
matrix. These chips can be made from cultured marble castings, thermoplastics, or even actual
granite stone that has been ground into particles. The cultured granite matrix usually consists of
polyester resin, initiator, colored chips, and ATH filler.

2. Solid Surface Molding:

Solid surface is a void-free casting made from a blend of polyester resin or acrylic resin, initiator,
ATH, color chips, and pigment.
Solid surface can be formulated to achieve a wide variety of looks and cosmetic effects, such as
simulating natural granite stone. For this reason, it is often used to manufacture products like
kitchen countertops.
In contrast to the gel coated surface of cultured marble, solid surface parts are homogeneous
throughout. This makes it possible to join fabricated pieces with inconspicuous seams and to
repair and refinish the surface to its original condition.
Solid surface, or densified, castings are made using vacuum-mixing techniques to produce a
matrix that is void free. This produces a material that presents a uniform surface when it is cut,
sanded, or bonded. Solid surface castings are post-cured at elevated temperatures (in the range

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of 200 degrees Fahrenheit) to enhance the physical properties of the matrix and produce a stable
product. Solid surface can be
compression molded, which is a high-
pressure, closed-molding process
suitable for molding high volumes of
complex solid surface parts. The
compression molding process uses
matched metal-heated molds mounted
in large hydraulic presses.
Compression molding produces fast molding cycles and high part uniformity but requires a high
capital investment in tooling and equipment. Features such as inserts, ribs, bosses or
attachments can be molded in. Good surface finishes can contribute to lower part-finishing costs.
Subsequent trimming and machining operations are minimized in compression molding. This
process is capital intensive and labor-efficient. Labor costs are low due to the fast cycle times and
reduced post-mold finishing, while capital costs are high for heated-metal tooling and molding
presses. Compression molding is a good option for large production volumes of uniform parts.

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