Session: 16-01-01: Government Agency Student Poster Competition

Paper Number: 150989

150989 - Rapid and Energy-Efficient Manufacturing of Fiber-Reinforced Composite Structures via a Novel Filament Winding Approach 

Filament winding is a widely used technique for manufacturing fiber-reinforced polymer composites. This method involves impregnating continuous fiber strands with resin and winding them onto a rotating mandrel using a winding machine. Traditionally, after the winding process, the composite material is vacuum-bagged and transferred to an oven for curing through long heating cycles. These conventional approaches are slow, energy-intensive, and cost-inefficient. The primary objective of this study is to significantly reduce the processing time, energy consumption, and cost associated with composite manufacturing by implementing in-situ curing during the filament winding process. More specifically, this involves applying infrared heat to the wound material via a remote photothermal source immediately after the winding process. By integrating this curing method directly into the winding process, the composite is cured and ready in a fraction of the traditional manufacturing time. This study investigates the effects of various parameters on temperature distribution and the degree of cure within the composite structure. Key parameters explored include the power output of the photothermal heat source, the rate at which the mandrel spins during curing, and the type of resin used. Understanding these parameters is crucial for achieving uniform curing throughout the composite, regardless of part thickness. To achieve our objectives, we utilize a custom-built filament winder, programmed with a single microcontroller, and constructed using off-the-shelf components within a limited budget. An infrared bulb is integrated to provide the localized thermal energy necessary for the rapid curing process. This setup allows us to conduct controlled experiments to fine-tune the curing parameters, ensuring that the composite materials are cured uniformly and efficiently. Our proof of concept demonstrates that carbon fiber composites can be cured in a significantly shorter time frame of five to ten minutes, depending on the part size, as opposed to several hours of heating in ovens or autoclaves. The data gathered from these experiments provide valuable insights into optimizing the curing process, ensuring consistency and quality in the final product. This rapid curing capability not only reduces the overall manufacturing time but also decreases energy consumption, making the process more cost-effective. The findings of this study highlight the potential for substantial advancements in composite manufacturing, promising reduced production times, lower energy consumption, and decreased costs. In addition, by refining the in-situ curing process, we can enhance the efficiency and scalability of composite production, benefiting a wide range of industries that rely on high-performance composite materials. Ultimately, this research paves the way for more sustainable and economically viable manufacturing practices in the composites industry.

Presenting Author: Rowan Vannier Colorado State University

Presenting Author Biography: I am a senior in mechanical engineering at Colorado State University, where I work as an Undergraduate Research Assistant at the Multifunctional Polymers and Composites Laboratory.

Authors:

Soroush Dashtizad Colorado State University
Rowan Vannier Colorado State University
Walter Jordan Colorado State University
Mostafa Yourdkhani Colorado State University