The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.

The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.

The increasing demand for polymer matrix composites (PMCs) from the airframe industry raises the issues of productivity, cost and reproducibility of manufactured PMC components. Performance reproducibility is closely related to the manufacturing technique. Resin transfer moulding (RTM) offers the advantage of flexible manufacturing of net-shape PMC components with superior repeatability starting from ready-to-impregnate dry reinforcements. An RTM apparatus was developed for manufacturing PMC plates and demonstrator components representative of actual, PMC components and PMC moulds made and used in the airframe industry. The RTM process developed in this work involved making net-shape dry carbon fibre preforms and impregnating them an epoxy resin, targeting mould applications. Thermal repeatability of different net-shape PMC components manufactured using the RTM apparatus developed in-house was investigated. Effects of bonding an outer copper plate onto the PMC material, targeting mould applications known as integrally heated copper tooling (IHCT), were explored. Heat conduction through the PMC components was studied using simulation models validated by experimental data obtained primarily by thermography. Manufactured PMC components showed good repeatability, particularly in terms of thermal behaviour. The IHCT technique was found to be well suited for mould applications. Expected advantages of thermography were materialised. Finally, the simulation models developed were in good agreement with experimental data.

Hybrid composites play a key role in sustainable development. For many years, carbon fibres in an epoxy matrix have been an attractive option for many structural applications because of their higher specific mechanical properties mostly. However, recycling and sustainability are some of the composite shortcomings; and in that context, natural fibres have gained popularity.  The present study aimed to design and manufacture short carbon/flax hybrid composites. Two different arrangements were chosen: random and layers configuration. Resin Transfer Moulding (RTM) was used to fabricate these hybrid composites. Mechanical tests and optical microscopy technique were conducted to understand the effect of the interaction of these two different reinforcements. Mechanical tests showed a remarkable difference between the hybrid configurations under flexural loadings. Furthermore, outstanding property values were observed in the hybrid configurations compared to single fibre composites. The resultant materials have seemed an attractive combination of fibres with a remarkable balance between mechanical performance and eco-friendliness.