Muhammad Anas Ali
F2024134021
University of Management and Technology
Department of Mechanical Engineering
Subject: ME-123: Engineering Materials
Topic
Hand lay-up method in composite manufacturing
Submitted to
Muhammad Abdullah Sheikh
Submitted by
Muhammad Anas Ali (F2024134021)
Muhammad Hassan Raza (F2024134027)
Ali Hassan (F2024134024)
Umer Shahzad (F2024134035)
Mehrab Ahmad (F2024134051)
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Muhammad Anas Ali
F2024134021
Table of Contents
Abstract Page 4
Introduction Page 4
Methodology Page 5
Advantages Page 6
Disadvantages Page 6
Applications Page 7
Result & Discussions Page 8
Conclusion Page 8
Referances Page 9
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F2024134021
Hand lay-up method in composite manufacturing
Figure 1. Schematic Diagram of Composite Hand
Layup Method[6]
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F2024134021
Abstract:
The fabrication and mechanical evaluation of glass fiber reinforced epoxy composites using the hand
layup method, a cost-effective and simple manufacturing technique. Epoxy resin served as the matrix
material, reinforced with glass fiber and enhanced by varying proportions of titanium dioxide (TiO₂) as a
filler. Six composite types were developed with constant glass fiber content and varying filler
concentrations. Mechanical properties including tensile, impact, hardness, compressive, and flexural
strength were tested. The results showed that incorporating TiO₂ improved the mechanical performance
of the composites compared to those without filler. Optimal properties were observed at different filler
levels: 15 wt% TiO₂ yielded the highest tensile strength, while 20–25 wt% TiO₂ showed maximum
performance in impact, hardness, compressive, and flexural tests. However, excessive filler content led
to reduced strength due to poor dispersion and bonding. Overall, the study concludes that moderate
addition of TiO₂ significantly enhances the composite's mechanical properties. [1]
Introduction
This study investigates the mechanical behavior of glass fiber-reinforced epoxy composites fabricated
using the cost-effective hand layup method. Epoxy resin served as the matrix, with glass fiber as
reinforcement and titanium dioxide (TiO₂) used as a filler in varying proportions. Six composite
formulations were tested to evaluate the impact of TiO₂ on tensile, impact, hardness, compressive, and
flexural properties. The results demonstrate that the inclusion of TiO₂ significantly enhances mechanical
performance, with optimal strength observed at specific filler concentrations. This work highlights the
potential for improving composite materials using affordable manufacturing techniques and filler
optimization. [1]
[1] [1]
Methodology of Hand Lay-up
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Figure 3. Showing hand lay-up processing [7]
Materials Preparation:
Fiber Reinforcements: First, we’ll prepare the fiber reinforcements. These can be in the form
of knitted, stitched, woven, or non-woven fabrics.
Resin Matrix: Next, we will select a thermoset resin matrix. Common resins include epoxy,
polyester, or vinyl ester.
Mold Preparation: A simple, single-cavity mold made of fiberglass composite construction is
used. The mold can vary in size from small to very large. A gel coat is applied to the mold using a spray
gun to create a high-quality surface finish.[2]
Lay-Up process:
1. Materials Used
E-glass woven fabric (EW185 cloth) was used as reinforcement, and Lycal epoxy resin
served as the matrix.
2. Manufacturing Methods Compared
Three composite manufacturing methods were used: hand lay-up, vacuum infusion, and
vacuum bagging.
3. Hand Lay-Up Process
Layers of glass fabric were manually laid in a mold. Resin was poured and spread by
hand using a brush. Each layer was rolled to remove air bubbles and then left to cure.
4. Vacuum Infusion Process
Dry glass fabric was placed in a mold, sealed with plastic and vacuum lines. Resin was
pulled into the mold using vacuum pressure for even distribution and better bonding.
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5. Vacuum Bagging Process
Resin and fabric were arranged like in hand lay-up, but then covered with a vacuum bag.
Pressure was applied through vacuum to remove air and compact the layers.
6. Specimen Preparation
After curing, composite sheets were cut into samples for testing according to ASTM
D3039 standards (standard for tensile testing of composites).
7. Mechanical Testing
Tensile strength and elastic modulus were measured using a Universal Testing Machine
(UTM) with constant loading speed.
8. Microscopic Analysis
Scanning Electron Microscope (SEM) was used to examine how well the resin bonded
with the fibers and to observe voids or defects in the composite structure.[2]
Advantages
1. Simple and Low-Cost Process
The hand lay-up method requires minimal equipment, making it accessible and cost-
effective for both small-scale and experimental use.
2. Good for Complex Shapes
It allows for flexible design and shaping, making it ideal for manufacturing parts with
complex geometries.
3. Easy Material Setup
Materials such as glass fiber and resin can be easily placed and adjusted by hand, offering
control over layer placement.
4. Suitable for Learning and Training
Because it’s manual, this method is useful for training operators and studying how
technique affects composite quality.[3]
Disadvantages
1. Operator Skill Affects Quality
The final strength and quality of the composite heavily depend on the worker’s
experience and technique, especially during impregnation and degassing.
2. Inconsistent Mechanical Properties
Results showed wide variation in tensile strength among samples, due to uneven resin
distribution and poor degassing by inexperienced operators.
3. Time-Consuming and Labor-Intensive
Each layer must be carefully placed and manually processed, which slows down
production and increases labor demand.
4. Risk of Air Bubbles (Voids)
Incomplete degassing leads to trapped air in the laminate, reducing the mechanical
strength of the composite.[3]
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Applications of Hand Lay-Up
1. Aerospace Parts
Used to make lightweight and strong parts for airplanes and spacecraft, such as panels
and covers.
2. Racing Cars
Helps build custom, high-strength body parts in motorsport vehicles, where performance
and weight matter most.
3. Sports Equipment
Commonly used to create items like tennis rackets, bikes, and helmets using carbon fiber
for better strength and feel.
4. Automotive Components
Useful for making car body parts, dashboards, or doors in both luxury and racing cars.
5. Wind Turbine Blades
Helps manufacture large, strong blades for wind turbines using layered composites.
6. Prototyping and Custom Manufacturing
Ideal for making one-off parts or prototypes quickly without expensive machinery.[4]
Results and Discussion
1. Eight Techniques Were Identified
Researchers studied how experienced workers lay down composite sheets by hand and
found 8 common techniques like guiding with one or two hands, folding material, and
applying tension in different ways to shape the material.
2. Different Tasks Needed Different Techniques
Not all techniques were used the same way. Simple shapes needed just basic guiding, but
complex or curved molds required shearing techniques to stretch or fold the material
to fit properly.
3. Mold Shape Affects the Method Used
The shape of the mold (flat, curved in, or curved out) affected which techniques were
helpful. For example:
o Flat molds: simple guiding was enough.
o Concave (curved-in) molds: needed folding and tension methods.
o Convex (curved-out) molds: required advanced tension and sticking to avoid
wrinkles or gaps.
4. Steeper Angles = More Work
Tasks with steeper ramps or deeper shapes needed more actions because the material
needed to stretch more, which often caused it to spring back or wrinkle—so workers had
to adjust it several times.
5. Why These Results Matter
Knowing which techniques work best for different shapes helps improve:
o Training for new workers,
o Design of parts that are easier to make,
o Future robots that could automate the layup process.
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6. Helpful for Automation
This research gives clear instructions on what human workers do, which can be used to
design robotic systems that can handle the same tasks in the future.[5]
(a ) (b )
Fibre pulls out
Voids
(c )
Broken fibre
Fig.4 SEM micrograph of fractured surfaces of (a) Composite S30, (b) composite UTK and
(c) composite TK [4]
Conclusion
In Summary, glass fiber and epoxy resin composite materials using a simple hand layup method. By
adding different amounts of titanium dioxide (TiO₂) powder, the strength of the material improved.
Tests showed that using 20% TiO₂ gave the best overall results for strength, toughness, and hardness.
Too much filler, however, made the material weaker. So, a moderate amount of TiO₂ makes the material
stronger and better for use.[1]
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References
[1] A. Al Mahmood, “Characterization of Glass Fibre Reinforced Polymer Composite Prepared by Hand
Layup Method,” Am. J. Biosci. Bioeng., vol. 5, no. 1, p. 8, 2017, doi: 10.11648/[Link].20170501.12.
[2] M. Migaki et al., “The Relationship Between Mechanical Properties and the Method Technique of
GFRP Plate by Hand Lay-up Method: Effect of the Workers Experience,” in Digital Human Modeling.
Applications in Health, Safety, Ergonomics and Risk Management: Human Modeling, vol. 9184, V. G.
Duffy, Ed., in Lecture Notes in Computer Science, vol. 9184. , Cham: Springer International
Publishing, 2015, pp. 143–153. doi: 10.1007/978-3-319-21073-5_15.
[3] K. Abdurohman, T. Satrio, N. L. Muzayadah, and Teten, “A comparison process between hand lay-
up, vacuum infusion and vacuum bagging method toward e-glass EW 185/lycal composites,” J. Phys.
Conf. Ser., vol. 1130, p. 012018, Nov. 2018, doi: 10.1088/1742-6596/1130/1/012018.
[4] C. N. A. Jaafar, I. Zainol, and M. A. M. Rizal, “PREPARATION AND CHARACTERISATION OF
EPOXY/SILICA/KENAF COMPOSITE USING HAND LAY-UP METHOD,” 2018.
[5] M. Elkington, D. Bloom, C. Ward, A. Chatzimichali, and K. Potter, “Hand layup: understanding the
manual process,” Adv. Manuf. Polym. Compos. Sci., vol. 1, no. 3, pp. 138–151, Jul. 2015, doi:
10.1080/20550340.2015.1114801.
[6] [Link]
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[7] [Link]