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aged material exhibiting greater void content. However, void content was also associated with the compaction quality, with greater laminate thicknesses leading to higher voids levels. Based on these observations, three defect reduction strategies were considered: intermediate debulking, variation in the mold corner radius, and the use of a pressure strip intensifier. Debulking was an effective means of reducing void content in laminates, providing evidence that air entrapped between plies during layup was a key source of voids. Increasing the mold corner radius improved quality by allowing the fiber bed to conform to the tool and reducing the potential for resin accumulation. The pressure strip effectively concentrated pressure in concave corners, and improved the quality of laminates fabricated on molds with tight corner radii, although air evacuation was partially impeded. The results presented here can be used as guidelines for reducing defects and optimizing a manufacturing cycle. For example, for a given laminate layup and geometry (corner angle), a concave molding set-up may be converted to a convex one to reduce defect levels. The results further indicated that this conversion is particularly important when transitioning from an autoclave to an OoA environment (e.g., vacuum bag). If concave tooling is specifically required, the local mold geometry can be modified to increase the corner radius and reduce resin accumulation. Moreover, a pressure strip can be used to further control local defects. Interestingly, the effects of increasing geometric complexity can be counteracted by relatively simple modifications to the mold corner radius or by using a pressure strip, enabling the fabrication of more aggressive geometries. Finally, for a generic set of prepreg, laminate, and molding conditions, these results provide approximate predictions for laminate quality. The shift from autoclave to non-autoclave manufacturing methods necessarily eliminates the safeguards associated with elevated pressure. As a result, the successful expansion of OoA DOI: 10.1002/pc.23773 22PDF Image | Vacuum Bag-Only Prepregs
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