CFRP layer-by-layer curing using research-based automated deposition system

Composite laminates of carbon fibres and a toughened snap-cure epoxy matrix were manufactured using a proof-of-concept layer-by-layer curing technique and compared to equivalent hot-press cured laminates. The layer-by-layer approach used a roller and a heated metal tool to deposit and cure a pre-preg layer to a degree-of-cure below gelation (α = 0.41) before applying the next layer, removing the need for a further curing step after deposition. The layer-by-layer process was found to produce laminates with evenly distributed micro-porosity (∼2.9 %), whereas press molded laminates at equivalent pressures featured higher porosity (∼4.7 %), that was concentrated in the inter-ply regions that were laminated together. Further work is needed to optimize the process variables for laminate quality, manage roller contamination, and study non-flat geometries.