COMPOSITE

MANUFACTURING
METHODS
ASSIGNMENT

submitted by
Ajay T R
Roll no: 3
semester 7

composite boat design

Contents
Introduc on ............................................................................................................................................ 3
1. Compression moulding .................................................................................................................. 4
2. Resin Transfer moulding ................................................................................................................ 5
3. Tube Rolling.................................................................................................................................... 7
4. Injec on Moulding ........................................................................................................................ 8
5. Centrifugal Cas ng ......................................................................................................................... 9
6. Con nuous Lamina ng ................................................................................................................ 11
Conclusion ............................................................................................................................................ 12
Reference .............................................................................................................................................. 13

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Introduc on
In today's society, composites are essen al to many industries because they can combine the best
a ributes of many different substances into one high-performance material. By combining two or
more dis nct materials, commonly a structurally strong fibre like carbon or glass with a resin
containing the binding agent, engineers are able to create structures that are lightweight but
astonishingly strong and defy wear. Today, composites are ubiquitous: aircra, fuselages, automo ve
parts, wind turbine blades, boats, sports equipment, engineering panels, etc. Many engineers are
a racted to composites because they can be designed for specific design and performance
requirements in ways that conven onal materials like steel or aluminium cannot.

This assignment will examine methods in composite manufacturing - processes that take raw materials
(fibres, resins, core structures, etc.) and transforms them into composite products in complex shapes
with specific strengths and excellent durability. Familiarity with underlying manufacturing processes
essen al for engineers working with advanced materials and to anyone interested in understanding
how new materials are changing the design and produc on landscape.

We will examine six main composite manufacturing processes that are in common use across mul ple
applica ons.

• Compression moulding, a high-pressure technique using heated materials formed in an

enclosed mould.
• Resin Transfer moulding (RTM), a way to inject liquid resin into a dry fibre shape that was
previously made in mould.
• Tube Rolling, a process used to produce hollow, cylindrical parts made from fibre-reinforced
materials, typically wound around a mandrel.
• Injec on moulding, a fast, bulk produc on method such that a liquid, composite material is
injected into a highly detailed mould,
• Centrifugal Cas ng, a method using rota onal forces to apply materials evenly and form
strong, desirable tubes or pipes without seams.
• Con nuous Lamina ng, a method using an automated process for producing flat or
corrugated composite panels made into con nuous rolls.

Each process is unique in terms of its benefits, limita ons, and intended applica ons. As part of this
exercise, we will evaluate not only how each process can occur but also where the processes are
mostly used, how and why those processing methods are selected over alterna ves, and who is
typically involved or responsible for these processes in the world of engineering and in industry at
scale. By framing our discussions around prac cal applica ons, we will develop a contextual and
physical understanding of developing composite fabrica on, along with other contributors, towards
integrated, efficient, reliable and innova ve solu ons in a selected discipline specific area. In our
explora on of these subjects, we will have a broader understanding of these key manufacturing
processes, not only technically, but contextual as contemporarily relevant technologies in the
interdisciplinary fabric of developing materials sciences.

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 1. Compression moulding

How-To:

The whole process begins with preparing a charge. It is not simply a charge; it is a pre-weighed, and
o,en pre-shaped, slug of thermoset plas c. The charge may take the form of a s ff sheet, or a puck of
material, and it almost always reinforced with either chopped fibres or a fabric mat (reinforcement)
Because this reinforcement makes the final part strong enough in which do use... Once the charge is
prepared, an operator will place the charge in the open, preheated, mould cavity. The mould is typically
made up of two halves, and been heated to required temperature. The top half of the mould, the
"plug" or "punch" comes down with tremendous force, closing the mould, and at this point the
transforma on occurs. The combina on of high temperature and pressure, forces the charge to flow
from the top of the mould cavity to the bo om as it fills the shape of the mould. The shaping alone is
interes ng, but along with the heat applied, anything made with thermoset plas c will go through a
chemical reac on where the thermoset plas c goes from liquid to a solid or cures, in a permanent
shape. Once the material has completely cured, the mould is opened, and the part is ejected. The
process is nothing short of incredible.

5 Ws:

• Who is using it? You've got engineers/designers and makers in the automo ve space using
this technique to manufacture things like body panels and bumpers. The aerospace industry
uses composite construc on for making lightweight, structurally sound components. The
electrical sector even relies on composites to provide the best proper es for some circuit
breaker parts, insula on, etc. Composites are valuable to anyone who needs to produce
many replicated, consistent parts that require high-quality material.
• What is it made from? It primarily uses a thermoset plas c that can only be hardened
permanently when heated. The opposite of thermoplas cs, thermoset plas cs cannot be

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 melted (and reshaped) again. The reinforcement (short glass or carbon fibre, or even fabric)
is blended with the plas c to create the high mechanical proper es of the final product.
• Where is it done? This is not a workshop process, but is done in connected manufacturing
plants. In these spaces, the layout includes specialized equipment, the most important being
a hydraulic press (that can develop hundreds to thousands of tons of pressure) and tooling
that has designated hea ng components.

• When is it a viable op on? If you have thousands, if not millions of the same part that you
need to make, primarily when it comes to parts with complicated detail, or geometry, then
compression moulding is your best op on. Compression moulding is an efficient and
repeatable manufacturing process that is meant for con nuous produc on.

• Why it's a/rac ve: Compression moulding has a fast lead- me and produces a part 'finished'
from the mould with an excellent surface finish. It is economically beneficial for high volume
manufacturing because minimal cycle me of processing and raw material cost will be small.
Compression moulding materials also demonstrate very high strength and excellent
dimensional stability so there won't be warping, or change in part dimension or shape;
making it very valuable for high performance parts which demand reliability of the part.

2. Resin Transfer moulding

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How-To:

The ini al step is to fabricate a preform, a pre-shaped mat of dry reinforcement fibres that can be
made from fiberglass, carbon fibre or Kevlar. This preform is where the part gets its strength and
shape, and it is posi oned in the mould cavity. Unlike compression moulding - where the material is
completely saturated with the resin, in RTM we load the mould with en rely dry reinforcement.

Then the mould is sealed and clamped together. This is very important as RTM is a closed-mould
process, and no air can get into the mould, and no resin can leave the mould. Once sealed, the two-
part liquid resin - usually an epoxy or polyester - is injected at low to moderate pressure. The resin is
generally a low-viscosity liquid, which allows it to flow easily and saturate the dry reinforcement
fibres, thereby expelling all of the air.

Once the resin fully fills the mould and completely we ed out the fibres, it is le, to cure. The cure
can be at room temperature or heat assisted depending on the resin system. A,er the resin has
hardened, the mould opens and removes the composite part.

5 Ws:

• Who uses it? RTM is primarily used by skilled technicians and engineers in industries with
rigorous standards for manufactured, structural parts. These include aerospace
manufacturers for aircra, fairings, the marine sector with boat hulls, and automo ve makers
of complex secondary structural components and body panels.
• What is it made of? The primal materials are a dry reinforcement fabric (fiberglass, carbon
fibre, etc.) and a low viscosity two-part resin. The resin components are mixed only just
before injec on to start the curing process. This facilitates the use of con nuous, high-
strength fabrics, which gives the resul ng part a significantly be er strength-to-weight ra o
than methods using chopped fibbers.
• Where is it done? RTM is done in specialized composite manufacturing plants. These plants
have dedicated closed moulds, sophis cated injec on machines that meter accurately and
mix the resin, and o,en, a vacuum pump to remove trapped air from the mould cavity.
• When is it a good alterna ve? This process is best for large, complex parts that you want to
have a good finish on both sides, and that you want to have a superior strength-to weight
ra o. It is more complex than some of the simpler open-mould processes, but s ll rela vely
easy to operate and if consistency is required, it is a suitable op on for moderate produc on
quan es.
• Why it's a/rac ve: The main advantages of RTM include possible parts with excellent
strengths, significant part-to-part consistency, and good surface finishes. The closed mould
provides significantly less vapour emissions of harmful vola le organic compounds (VOCs),
therefore is environmentally friendlier compared to tradi onal open-mould processes. RTM
allows for ul mate convenience to add core or insert placement in to the process, very li le
post processing is required.

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 3. Tube Rolling

How-To:

The process starts with a mandrel, a cylindrical rod that dis nguished by its accuracy - almost always
made from steel or aluminium - which of course acts as the mandrel and determines the final inner
diameter of the resul ng tube. The next component is called the pre-preg, which is a type of special
fabric - such as carbon fibre or fiberglass - which has been pre-impregnated with a defined amount
of uncured resin to subsequently get rid of any uncertainty about adding resin later, and make sure
of the ra o every me.

A skilled technician carefully cuts and lays up the sheets of pre-preg (or similar alterna ve),
transferring and wrapping them around the mandrel, and at this point we see the magic - as we can
change the angle of each layer, we can precisely specify each layer�s fibre orienta on. An example
would be if one layer was at a 0-degree direc on for the longitudinal s ffness, and another would
perhaps be a 45-degree layer to give torsional strength which would allow for customiza on - this is a
big reason for the value of tube rolling in custom or high-performance applica ons.

A,er the layers are wrapped, we need to compact the part - this is normally done by applying
pressure to the layup with a special type tape, as the tape is heated, it shrinks, which is another way
to apply pressure. The whole set up, mandrel, pre-preg and shrink tape are taken to a curing oven.

5 Ws:

• Who uses it? You'll see this kind of work typically done by skilled technicians and engineers
in niche manufacturing shops. They will likely be making high-performance sports
equipment, aerospace applica ons, or industrial parts that depend on weight-to-strength
ra o.
• What is it made of? The most important material is pre-preg—essen ally a "ready to go"
reinforcement fabric like carbon fibre or fiberglass that has been pre-impregnated with a
precise ra o of resin. This removes the messy side of working with resin, and ensures there
will be consistency from part to part.

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 • Where does it take place? Tube rolling happens in specialized shops that have specialized
tools; cuJng tables, tools to create various mandrels, and curing equipment such as ovens
or autoclaves.
• When is it the best choice? When you are looking to manufacture extremely strong, light
weight hollow tubes and sha,s, this is the method for you. This process is ideal for anything
that needs to be strong and s ff, but not heavy; golf sha,s, bicycle frames, drone booms, etc.
• Why is it so easy to use? First and foremost, the biggest reason is that it offers surplus
control of fibre orienta on. You can engineer parts with incredible s ffness and strength
exactly there you need it, which is nearly impossible to do with other methods.

4. Injec on Moulding

How-To:

The process begins with thermoplas c pellets, which are loaded into a large hopper. But these are
not just any pellets; they are usually reinforced with chopped fibres, such as glass or carbon, to
provide addi onal strength and s ffness to the final product. The pellets feed into the heated barrel,
where a rota ng screw melts the pellets and pushes them forward. The heat and pressure change
the pellets into a viscous, liquid-like state, suitable for injec on.

The liquid is then injected into a closed, temperature-controlled mould cavity with high pressure,
using either a ram or screw to inject the molten plas c. The mould is an incredible piece of
engineering, usually constructed from hardened steel and precision machined to a specific shape of
the required part. Since the plas c is injected under pressure, it fills every detail of the mould cavity,
ensuring a perfect part.

Once the mould cavity is full, it will hold that state under pressure for a short period of me. This is
known as the holding or packing phase, and is cri cal to ensure no voids or sink marks occur as the
plas c cools and shrinks. Cooling is a cri cal aspect, because as soon as it has solidified, the mould
will open, and the finished part will be quickly ejected.

5 Ws:

• Who uses it? O,en mes, injec on moulding machines are run by automa on, but generally,
they are run by skilled technicians, and everything is produced in large factories around the

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 world. This process is cri cal to mass producers across many industries, including automo ve,
medical, electronics, and consumer goods, just to name a few.
• What is it made of? The raw material used in injec on moulding is generally thermoplas c
pellets. The difference between thermoplas cs and thermosets is very important. Thermosets
harden permanently, whereas thermoplas cs can be melted down and re-moulded - which
means that scrap plas c can be recycled! The addi on of short fibres, to the thermoplas c,
can produce be er mechanical proper es in the final part.
• Where does it happen? Each injec on moulding machine is massive and o,en, complex piece
of equipment that ul mately works within an industrial plant (or in an industrial context).
Industrial plants for injec on moulding are o,en set up for high-volume produc on, with
conveyor belts and robots taking component parts out of the moulds.
• When to choose this? It's the best op on for mass produc on. Injec on moulding is the
answer if you need to produce millions of small to medium sized complex parts with ght
tolerances and consistent quality.
• Why is it so popular? Nothing comes even close to its speed and efficiency. It is incredibly fast
with incredibly high rates of produc on. It is also highly repeatable meaning every part coming
from the mould is a virtual copy. With all of these factors the speed, consistency, cheapness is
the reason Injec on moulding is the most popular and most powerful op on to manufacture
plas c parts today.

5. Centrifugal Cas ng

How-To:

The process is begun with the use of a custom cylindrical mould designed to spin at very high speeds.
The operators prepare a mixture of liquid resin (typically polyester or epoxy), along with fibreglass or
a con nuous fibre mat as reinforcement. The mixture is then poured into the spinning mould.

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Once the mould begins rota ng, the centrifugal force takes hold. This significant force pushes the
en re composite mixture against the mould wall, crea ng the shape of the part itself. The centrifugal
force also serves a cri cal role, which is to displace any air bubbles that may be trapped in the
composite, and pushes the resin and reinforcement fibre ghtly together, crea ng a "void-free" and
dense part.

The mould con nues to spin as the resin is curing (which is accelerated by hea ng), un l it is
completely cured and solid, at which point the mould is no longer spinning. The finished composite
pipe or tube is extracted from the mould. The final outcome is a complete, deeply-cured, strong, and
cylindrical part that is very consistent, dense, and has smooth inner and outer surfaces.

5 Ws:

• Who uses it? You will find operators and engineers using this process in specialized facili es
to make products for infrastructure and industrial facili es. This is an important process for
manufacturers of water pipe, storage tanks, and other hollow cylindrical products.
• What is it made of? Usually, the raw materials are a liquid resin and a reinforcement material.
The resin (vinyl ester or epoxy) and the reinforcement (fiberglass, carbon fibre) vary, based on
the final products desired strength, chemical resistance, and durability.
• Where does it happen? This process is done in specialized facili es with rota ng moulds, and
curing equipment to cure the product. The moulds require balancing and must be strong
enough to withstand the high speeds that the process generates.
• When is it appropriate? This method is used solely when you desire a hollow cylindrical part
with no defects, density and strength. If you are crea ng a pipe for a chemical plant or high-
pressure line, you require a defect-free part. Centrifugal cas ng is an effec ve means of
achieving that.
• Why is it so desirable? The major benefit is the quality of the final part. The centrifugal force
results in a consistent wall thickness and pushes out the air bubbles that typically occur while
processing composites by other means. You will obtain a composite material with superior
mechanical proper es, excellent reliability and a service life that is extremely long.

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 6. Con nuous Lamina ng

How-To:

The process starts with a long conveyor belt or "carrier film", which is the bo om layer of the
sandwich. As the film moves along the line, a liquid resin, most typically polyester or vinyl ester, is
precisely applied to the film. It's kind of like a long, orderly coat of paint applied to the surface of the
film.

Upon applying the resin, the process con nues with a con nuous input of a reinforcement material,
most commonly a fiberglass mat or woven fabric, is applied to the liquid resin. This is where the
strength comes from. The resin soaks into the fibres and creates a strong bond. Subsequently, the
second film is applied to the top layer, comple ng the "sandwich."

This en re composite sandwich now goes into a heated die or oven. This is the curing stage. The heat
will ac vate the resin which causes it to harden and permanently bond the fiberglass and films
together to form a solid, rigid composite. As the material leaves the oven, it is a finished solid panel.
The line operator cuts the con nuous panel with an automated saw into the desired lengths for
shipping. The speed and efficient means of producing composite panels makes it an economical
process for mass produc on.

5 Ws:

• Who uses it? This process is primarily handled by automated machinery, but there’s a small
team of operators who keep an eye on everything and ensure quality control. You’ll typically
find this technology in factories that produce building materials, components for
transporta on, and various industrial products where strong yet lightweight panels are
essen al.
• What's it made of? The main ingredients in this process include a liquid resin and a steady
supply of reinforcement materials. Polyester and vinyl ester resins are popular choices
because they strike a good balance between strength and affordability. The reinforcement
material is o,en fiberglass, which comes in different forms like mats, rovings, or woven
fabrics, providing the necessary structural support.

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 • Where does it happen? This manufacturing method is found in large industrial facili es
designed around a con nuous processing line. Picture a factory that operates like a giant
machine, where raw materials are fed in one end and finished panels emerge from the other,
crea ng a smooth and efficient produc on flow.
• When should you choose con nuous lamina ng? This method shines when you're looking
to produce a large number of flat or corrugated panels consistently and cost-effec vely. If
you're working on a big construc on project or managing a fleet of trucks, this approach is
hard to match.
• why is it so widely favoured? The key draws are its cost-effec veness and impressive
efficiency. Because the process is con nuous and automated, it requires less manual labor,
speeds up produc on mes, and delivers consistently high-quality products. This method
makes it possible to mass-produce robust and durable composite sheets that can be used in
a variety of applica ons, from building truck trailer walls to crea ng translucent roofing. It's a
prac cal choice for anyone needing reliable materials in bulk.

Conclusion
A,er exploring different composite manufacturing methods, it’s become apparent that there isn't a
one-size-fits-all solu on. This assignment has revealed a range of unique techniques, each cra,ed to
meet specific needs.

Selec ng a manufacturing method is a thoughPul process that hinges on a solid grasp of what the
product requires. For example, the efficiency and consistency of injec on moulding make it perfect
for mass produc on, while the precise, hands-on nature of tube rolling is key for crea ng high-
performance, customized components.

It's in this context where the human touch really shines. These processes are more than just
mechanical opera ons—they reflect the crea vity and exper se of engineers and technicians who
carefully choose the best approach to strike the right balance between strength, weight, and cost. By
delving into these various techniques, we not only learn about the manufacturing process but also
come to appreciate the skill and care that go into cra,ing the products we rely on in our everyday
lives.

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Reference
General Composite Manufacturing:

• h/ps://[Link]/composites-manufacturing-processes/

Compression Moulding:

• ScienceDirect – Compression Molding

• h ps://[Link]/learn/process/compression-moulding

Resin Transfer moulding (RTM)

• ScienceDirect – Resin Transfer Molding

• h ps://[Link]/zones/resin-transfer-molding-rtm

Tube Rolling (Roll Wrapping / Filament Winding)

• h ps://[Link]/ar cles/processes/roll-wrapping/
• h ps://[Link]/filament-winding/

Injec on Molding (with Composites)

• ScienceDirect – Injec on Molding

• h ps://[Link] [Link]/technologies/injec on-molding/

Centrifugal Cas ng

• ResearchGate – Centrifugal Cas ng for Composites

• h ps://[Link]/blog/what-is-centrifugal-cas ng/

Con nuous Lamina ng

• MDPI Open Access – Composite Panel Manufacturing

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