How to Make a Composite—Wet Layup

This chapter introduces the six basic steps needed to design and make a fibre-reinforced composite (FRC): (1) fibre and matrix selection; (2) mould preparation; (3) layup and consolidation; (4) curing (and post-curing); (5) demoulding; and (6) post-processing (finishing). These six steps are considered using a simple wet layup process for a flat unidirectional (UD) composite. The mechanical performance of the composite is estimated based on the rule of mixtures (RoM), inverse rule of mixtures (IRoM) and Kelly-Tyson (KT) models from Chap. 2. A description of the wet layup process is offered and discussed in the context of the options available to a composite fabricator. The chemical crosslinking processes for polyester, vinylester and epoxy are presented. Consideration is given to demoulding the FRC and to the post-processing options. The use of gelcoat, flow coat and paint are mentioned in the context of a broader discussion on surface finishing of FRC. The outcome of the chapter is a step-by-step design and manufacturing method that is easily replicated.