A Parametric Study on Compression Molding of Reference Parts with Integrated Features Using Carbon Composite Production Waste

Compression molding of near net-shaped rib-stiffened plates has been performed for a parametric investigation on the filling behavior of chopped woven flake reinforcements. The experimental investigation showed that different aspect ratios of ribs can be filled completely within the tested maximum ratio of flake size to rib opening width of 6.25 and a maximum consolidation pressure of 15 bar. However, defects such as voids, non-impregnated regions and fiber matrix separation may arise depending on the combination of parameters and a mechanical jamming effect caused by the woven architecture of the flakes. A tendency for a limiting consolidation pressure is observed based on the fiber matrix separation. The ability to re-use thermoplastic prepreg cutting waste has been demonstrated.