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severe in-plane misalignments. Brillant and Hubert [10,19] studied the effect of different bagging configurations on thickness uniformity and void content in L-shaped concave and convex laminates with various laminate thicknesses and corner radii. Their results showed that void content and thickness variation could be greatly influenced by lay-up strategies. Levy et al. [20] proposed an analytical corner compaction model for L-shaped laminates that accounted for local pressure difference and interplay friction, and data from the model agreed with experiments. Cauberghs and Hubert [21] focused on the effect of Z-shaped tight corner geometry with one convex corner between two concave corners and the levels of connectivity required between ply drop-offs and the vacuum source. They showed that resin accumulation in concave corner regions was associated with consumable bridging, and low void content could be achieved by connecting the dropped plies to the vacuum source. More complex OoA/VBO composite structures were also evaluated in previous studies. For example, Grunenfelder et al. [22] studied the void content in embedded doublers that consisted of a local build-up of additional plies in regions of laminates and hat-stiffeners. Results showed that voids within the embedded plies could be reduced by fostering air evacuation through prepreg plies impregnated on only one side and longer vacuum hold times prior to cure. Finally, Hughes and Hubert [23] investigated how quality changes with part size and complexity scale-up. They observed that while the microstructural quality of small-scale samples was indicative of what were observed in samples extracted from a large-scale part, the physical and manufacturing parameters governing part quality could interact to increase void content and render industrial-scale manufacturing challenging. The literature cited above clarified several phenomena governing the manufacturing of complex shapes, and confirmed that deviations from a flat geometry introduce additional defect DOI: 10.1002/pc.23773 5PDF Image | Vacuum Bag-Only Prepregs
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