1.
Polymer Matrix Composites (PMCs)
Introduction to PMC:
Polymer Matrix Composites (PMCs) are materials made by combining a
polymer resin (such as epoxy or polyester) with reinforcing fibers (like glass,
carbon, or aramid) to improve strength, stiffness, and durability. The polymer
acts as the matrix that binds and protects the fibers, while the fibers provide the
load-carrying capacity. PMCs are widely used because they are lightweight,
corrosion-resistant, and customizable for different mechanical and thermal
properties.
List of PMC Processes:
Hand Lay-up Process
Spray-up Process
Filament Winding Process
Pultrusion Process
Resin Transfer Molding (RTM) Process
Autoclave Molding Process
1.Hand Layup
The Hand Layup method is the simplest and oldest process used for fabricating
PMC components. It is a manual process where fibers are placed by hand in a
mold and resin is manually applied.
Working Principle:
1. Mold Preparation:
○ The mold surface is cleaned and treated with a release agent.
2. Fiber Placement:
○ Dry fiber sheets (like fiberglass mats or woven fabrics) are cut and
manually laid onto the mold surface.
3. Resin Application:
○ Liquid resin (like polyester, epoxy) is manually poured or brushed
over the fibers.
4. Impregnation:
○ Rollers or brushes are used to ensure complete wetting of fibers
and to remove trapped air bubbles (de-airing).
5. Curing:
○ The layup is allowed to cure at room temperature or slightly
elevated temperatures, sometimes with slight vacuum or pressure.
6. Demolding:
○ After curing, the final composite part is removed from the mold
and trimmed as needed.
Advantages:
● Low cost: No expensive machinery required.
● Simple process: Easy to learn and set up.
● Flexible: Suitable for making complex shapes and large parts.
● Customizable: Fiber orientation and thickness can be easily varied.
Disadvantages:
● Labor-intensive: Requires skilled manual labor.
● Low production rate: Not suitable for mass production.
● Quality variation: Dependent on worker skill; inconsistent properties.
● Poor fiber volume control: Less efficient mechanical properties
compared to automated methods.
Applications:
● Boat hulls and marine structures
● Aircraft radomes and fairings
● Wind turbine blades
● Automotive body parts
● Sporting goods like kayaks and surfboards
2.Spray-Up Technique
The Spray-Up Technique (also called Spray Layup) is a semi-automated
fabrication method used to quickly produce composite parts by spraying a
mixture of chopped fibers and resin directly onto a mold.
Working Principle:
1. Mold Preparation:
○ The mold surface is cleaned and coated with a release agent and
sometimes a gel coat for better finish.
2. Spray Application:
○ A special spray gun simultaneously sprays chopped fiber strands
(usually glass fibers) and liquid resin onto the mold surface.
3. Rolling:
○ A roller is used to compact the sprayed material, remove air
bubbles, and ensure proper fiber-resin wetting.
4. Layering:
○ Multiple layers are sprayed to achieve the desired thickness and
strength.
5. Curing:
○ The part is left to cure at room temperature or under controlled heat
conditions.
6. Demolding:
○ After curing, the composite part is removed from the mold and
trimmed to the final shape.
Advantages:
● Fast production: Suitable for making large parts quickly.
● Lower labor cost: Less manual work compared to hand layup.
● Good for complex shapes: Easily covers curved and large surfaces.
● Flexible thickness: Thickness can be controlled by the number of spray
passes.
Disadvantages:
● Limited fiber control: Fiber orientation is random, leading to lower
strength compared to other methods.
● Health hazards: Spraying produces fumes and fine fibers; needs proper
ventilation and personal protective equipment.
● Surface finish: Surface quality may not be as smooth without a gel coat.
● Not suitable for high-performance parts: Mechanical properties are
lower compared to pre-preg or hand layup methods with carefully placed
fibers.
Applications:
● Large boat hulls and marine parts
● Bathtubs, shower stalls
● Automotive body panels
● Storage tanks
● Recreational vehicle (RV) parts
3.Filament Winding
Filament Winding is a highly efficient and automated manufacturing process
used to produce hollow, cylindrical, or spherical composite structures by
winding continuous fiber strands soaked in resin onto a rotating mandrel.
Working Principle:
1. Mandrel Preparation:
○ A mandrel (the shape over which fibers are wound) is prepared and
sometimes coated with a release agent.
2. Fiber Impregnation:
○ Continuous fiber strands (like glass, carbon, or aramid) are drawn
through a resin bath where they are thoroughly wetted with
polymer resin.
3. Winding:
○ The resin-wetted fibers are wound onto the rotating mandrel in
specific patterns (like helical, hoop, or polar winding) depending
on the strength requirements.
4. Curing:
○ After winding, the part is either left to cure at room temperature or
heated in an oven.
5. Mandrel Removal:
○ Once cured, the mandrel is removed, leaving behind the finished
hollow composite structure.
Advantages:
● High strength and stiffness: Especially in the fiber direction.
● Automated process: Reduces human error and improves consistency.
● Material efficiency: Very little wastage of fiber and resin.
● Customizable properties: Fiber orientation and number of layers can be
designed based on strength needs.
● Suitable for high-pressure applications: Strong resistance to internal
and external pressures.
Disadvantages:
● Limited to simple shapes: Mainly cylindrical, spherical, or slightly
conical parts.
High setup cost: Requires specialized winding machines.
● Mandrel removal can be difficult: Especially for complex internal
geometries.
● Less suitable for flat or very complex parts.
Applications:
● Pressure vessels (like CNG tanks, oxygen bottles)
● Rocket motor casings
● Pipes and ducts for industrial use
● Aircraft and spacecraft components (fuel tanks, radomes)
● Sports equipment (like fishing rods, golf club shafts)
4.Pultrusion Process
Pultrusion is a continuous manufacturing process used to produce long, constant
cross-sectional composite parts by pulling fibers through a resin bath and then
shaping and curing them in a heated die. It is highly efficient for making
structural components
Working Principle:
1. Fiber Feeding:
○ Continuous fiber rovings (such as glass, carbon, or aramid) are
drawn from creels and fed into the process.
2. Resin Impregnation:
○ The fibers pass through a resin bath where they are fully wetted
with a polymer resin (like polyester, vinyl ester, or epoxy).
3. Pre-forming:
○ After resin impregnation, fibers are organized into the desired
shape using a guiding system.
4. Die Entry:
○ The wetted fibers are pulled into a heated die that shapes the
material and initiates curing (hardening) of the resin.
5. Pulling and Cutting:
○ A pulling mechanism continuously pulls the cured composite
through the die, and it is then cut into required lengths.
Advantages:
● Continuous production: Ideal for high-volume manufacturing.
● High strength and stiffness: Good mechanical properties along the fiber
direction.
● Excellent dimensional accuracy: Uniform cross-sections with good
surface finish.
● Cost-effective: Lower labor costs and material wastage.
● Corrosion-resistant: Suitable for harsh environments.
Disadvantages:
● Limited shapes: Only straight profiles with constant cross-sections can be
made (no curves).
● High initial setup cost: Expensive dies and machinery.
● Design limitations: Difficult to create complex or varying shapes.
● Material restrictions: Best suited for thermoset resins; thermoplastics are
more challenging.
Applications:
● Structural beams and frames (I-beams, channels)
● Ladder rails
● Cable trays
● Window frames and door profiles
● Fishing rods and sports equipment
● Infrastructure like bridge components and handrails
5.Resin Transfer Molding (RTM)
Resin Transfer Molding (RTM) is a closed-mold composite manufacturing
process where dry fibers are placed inside a mold and liquid resin is injected
under pressure, filling the mold and impregnating the fibers. This process allows
for high-quality and complex composite parts with smooth surface finishes on
both sides.
Working Principle:
1. Mold Preparation:
○ A two-part mold (usually made of metal) is cleaned, coated with a
release agent, and prepared.
2. Fiber Placement:
○ Dry fiber preforms (woven fabrics or mats) are placed into the
lower half of the mold.
3. Mold Closure:
○ The upper half of the mold is closed and sealed tightly.
4. Resin Injection:
○ Liquid resin (like polyester, epoxy, or vinyl ester) is injected under
low to moderate pressure into the mold, filling all spaces and
impregnating the fiber layers.
5. Curing:
○ The resin is allowed to cure inside the mold, usually at room
temperature or slightly elevated temperatures.
6. Demolding:
○ After curing, the mold is opened, and the finished composite part is
removed.
Advantages:
● Good surface finish: Smooth on both sides of the part.
● Complex shapes: Can produce intricate and detailed parts.
● Less labor-intensive: Compared to hand layup methods.
● Low void content: Produces strong and durable parts.
● Efficient material use: Reduces resin wastage and ensures good fiber
wet-out.
Disadvantages:
● High mold cost: Expensive molds are required.
● Setup time: Preparing molds and preforms can be time-consuming.
● Limited fiber volume: Fiber content may be lower compared to other
methods like filament winding.
● Resin viscosity: Only low-viscosity resins can be used easily.
Applications:
● Automotive body panels (hoods, doors, bumpers)
● Aerospace parts (fairings, ducts)
● Boat hulls and marine components
● Sporting goods (helmets, bicycle frames)
● Industrial equipment housings and covers
6.Autoclave Molding
Autoclave Molding is an advanced manufacturing process where
fiber-reinforced resin materials (typically pre-pregs) are laid into a mold and
then cured inside a high-pressure autoclave. This technique produces very
high-quality composites with excellent strength, stiffness, and surface finish,
commonly used in aerospace and high-performance industries.
Working Principle:
1. Layup Preparation:
○ Pre-impregnated fiber sheets (pre-pregs) are hand-laid into a mold
in the desired shape and orientation.
2. Vacuum Bagging:
○ The layup is covered with a release film, breather, and sealed inside
a vacuum bag to remove air and control resin flow.
3. Vacuum Application:
○ A vacuum is applied to compact the layers and remove trapped air.
4. Autoclave Processing:
○ The mold is placed inside an autoclave (a high-pressure oven).
Heat and pressure (usually 120–180°C and up to 7 bars pressure)
are applied simultaneously.
5. Curing:
○ The heat activates the resin to flow and cure, while pressure
consolidates the layers for a dense, void-free part.
6. Cooling and Demolding:
○ After the part is fully cured, it is cooled, and then removed from
the mold.
Advantages:
● High-quality parts: Very low void content and high fiber volume
fraction.
● Excellent mechanical properties: Superior strength, stiffness, and
durability.
● Good surface finish: Smooth and professional-looking surfaces.
● Precise control: Temperature, pressure, and vacuum control lead to
consistent results.
Disadvantages:
● Expensive equipment: Autoclaves are costly to buy and maintain.
● High operating costs: Requires skilled labor and energy consumption is
high.
● Limited size: Size of parts is limited by the size of the autoclave.
● Long production time: Multiple steps like layup, bagging, and curing
take time.
Applications:
● Aerospace structures (wings, fuselage parts, tail sections)
● Military components (radomes, armor panels)
● Automotive (high-end race car body parts)
● Sporting goods (tennis rackets, bicycles)
● Satellite and spacecraft parts
