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sources during VBO processing. However, the fundamental aspects of VBO prepreg compaction, which are affected by local regions with complex geometry, remain unclear. Moreover, most studies have focused on L-shaped or C-shaped laminates with 90° angles, and have not analyzed the effects of other geometries, or of increasing geometric complexity. Finally, effective strategies to limit defect levels and ensure part quality remain elusive, but highly sought after. 1.1Objectives and Structure Several factors are typically considered during studies that seek to optimize processing. Some, including the prepreg format and ply stacking sequence, are “intrinsic” to the part and cannot be easily adjusted due to material availability, design constraints, and desired mechanical properties. Others, such as processing conditions and tool design, are “extrinsic” and can be altered to maximize quality if the relevant scientific relationships are understood. In this work, we seek to identify the effect of key processing conditions and tool characteristics (extrinsic factors) on part quality for several prepreg and laminate combinations (intrinsic factors). We focused on a generic part geometry consisting of a corner located between two flanges. First, we studied the effect of increasing geometry complexity by varying tool corner angles for two prepreg materials and various thicknesses. Then, we investigated three feasible process modifications: variation to local corner radii, the use of intermediate vacuum hold prior to oven cure, and the application of pressure intensifiers at corners. This study aims to expand the existing knowledge of OoA processing by clarifying the compaction mechanisms that lead to defects in complex shape laminates, and form the basis for practical guidelines for the selection of mold designs and processing parameters that mitigate defects and improve part quality. DOI: 10.1002/pc.23773 6PDF Image | Vacuum Bag-Only Prepregs
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