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high performance two part resin systems may cure too fast to be satisfactorily used in VARTM processes for large structures, and the waste and extra labor required for the resin distribution channels is costly. Based on our lessons learned from these programs, Sunrez has conceived of and plans to develop a new low cost robust VARTM process (the LS VARTM Process) which can impregnate any large scale fabric or fibrous reinforcements very quickly and completely to 60-70%byfiberweightwithinafewminutes. Thisprocesseliminatestheunderthebag distribution media associated with current VARTM processes and at the same time uses very little auxiliary materials and is very general with respect to what part shapes and sizes can be fabricated. Elimination of the under bag distribution media will reduce both touch labor and costs of materials associated with other VARTM Systems used in many large Naval composite projectstoday. Theeliminationofthesedistributionmediareducestheamountofmaterials which go directly to the trash can after the part is removed from the mold. Additionally, less resin is required to build a part since the flow media can contain a significant amount of resin. In fact, in thinner laminates there can be more resin in the flow media than in the laminate. The elimination of this distribution media will also allow the fabricator to directly see the laminate prior to and during cure. This gives the fabricator the opportunity to address and fix any areas of the laminate which may not have infused properly or may need additional attention. Thevalueofbeingabletoviewthelaminateandseeanyresinpoorareasordry spotspriortocureissignificant. Theamountoflabortorepairapartafteritisoutofthemold canbealmostashighastheamountoflabortoproducethepartoriginally. Eliminationofthe distribution media will cut both time and materials from the lamination of large and small parts. This SBIR will concentrate on proving and developing the LS VARTM Process to make it a more robust and reliable system while not using any distribution media under the bag. Since the LS VARTM Process can be checked visually, exploration will be done on assuring an infusion pattern that will insure complete laminate wetout. This new LS VARTM Process can readily handle fast curing resins, higher viscosity resins, epoxies and other standard one- and two-part resins together with standard high performance reinforcementssuchasKevlarandcarbonfibers. SincetheLSVARTMprocesscan impregnate preforms and fabric reinforcements so rapidly, it can be used to quickly impregnate fast curing high performance two part resins which normally have too short a working life to utilize standard VARTM processes such as SCRIMP or the Sunrez processes already demonstrated on the Navy Advanced Composite Ship Hull Program. The LS VARTM Process can handle very large structures (areas) and eliminates the waste materials and labor associated with resin distribution channels and flow media while at the same time being very fast. Based on the previous Sunrez experience with VARTM processes for large parts and structures, and our initial exploratory development experience with the LS VARTM Process, we believe that the total manufacturing costs for large scale and small scale composite parts would approach the cost of the materials actually used in the composite with only a small labor cost and virtually no waste or set up materials cost in contrast to what is currently -2-PDF Image | Affordable NDM Vacuum Assisted Resin Transfer Molding
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