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encounteredwithotherVARTMprocesses. ItisimportanttorememberthatVARTM processes use vacuum on the inside of a bag with atmospheric pressure on the outside of a bagtoaccomplishupto14.7psipressureforcompactionofthelaminate. Inaddition,a good vacuum degasses a composite part better than pressure prior to curing. Sunrez believes that the LS VARTM Process is the manufacturing breakthrough that has been needed to make the VARTM manufacturing approach a robust low cost process for all reinforcements and thermoset resins. In this proposed program, Sunrez seeks to demonstrate the versatility of this process for various shapes and sizes of composites but focusing on the basic NAVY needs as described in N99-097 utilizing a Navy approved vinyl ester resin and glass fiber reinforcements. An initial estimate of the man hours required per pound of composite part produced by the LS VARTM Process is 0.1 man hours per pound on moderate sized structures. (Our work with the Advanced Composite Ship Hull program demonstrated that less than 0.2 man hours per pound composite with light cured resin processes were achievable even with prototype parts.) Even lower labor costs would be expected on repetitiveproductionrunsfromthesamemold. ItmustbeemphasizedthattheVARTM processes do not use autoclaves, do utilize low cost molds, and are essentially free of chemical vapor release. The LS VARTM Process is the latest and the largest advance in this technology in over 15 years. 1.2. Technical Description of Opportunity. Sunrez deliberately set out to conceive and develop the LS VARTM Process in order to find the fastest and lowest cost possible VARTM process and to be able to utilize two-part resins and opaque reinforcements. This meant the elimination of resin distribution tubes and the maximizingtheflowrateoftheresinoverthetopofthereinforcementstack. These advantages have been demonstrated in this Phase I proposal. The versatility and any limits for this process will be determined in Phase II. The LS VARTM Process has very wide possibilitieswhichweareonlybeginningtoexplore. Sunrezhasonlydescribedthisprocess to a few companies and we have filed for patent protection. We have had some difficultly in explaining this process to others for the first time because it is truly a different approach. Therefore it is recommended that the reader actually make a model of the process as described to more easily understand the process. The overall technical objective for Phase I is to demonstrate that the LS VARTM Process can eliminate all consumable waste, resin distribution media, tubes and excess resin, while at the sametimedramaticallyreducingtouchlaborandoverallpartscost. Inaddition,afurther technical objective is to demonstrate the versatility of the LS VARTM Process for fabricating large scale parts (hundreds of square feet in size) containing cores, stealth materials, skin thicknessesoveroneinch,andstructureswithnonuniformcross-section. Inmeetingthese overall objectives, the LS VARTM Process should be the prime candidate VARTM process which is needed to achieve low cost composite manufacturing of large Navy structures. The lower composite manufacturing costs with the LS VARTM process will also have a significant impact on manufacturing in the industrial/commercial market including infrastructure, automotive, transportation and marine applications.PDF Image | Affordable NDM Vacuum Assisted Resin Transfer Molding
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