How the Prepreg Autoclave Process works
The process uses prepregs (pre-impregnated fibre mats or fabrics, usually with epoxy resin), which are cured under defined conditions in an autoclave.
Process
- Prepreg Cutting and Layerup: The prepregs are cut to the required shape and arranged in layers on a tool (mould). The fibre orientation is precsiely defined to achieve the desired mechanical properties.
- Vacuuming: The layers are covered with a release film, a venting layer, and a vacuum film. A vacuum is then applied to eliminate air pockets and increase the density of the laminate.
- Autoclave Curing: The component is cured in an autoclave at an elevated temperature (e.g., 120-180 °C) and pressure (e.g., 6-10 bar). The pressure and temperature ensure the fibres are optimally impregnated, porosity is reduced and the material properties are improved.
- Demoulding and Post-processing: After curing, the component is removed from the mould an, if necessary, undergoes mechanical post-processing (e.g., cutting or drilling).
Advantages of the Prepreg Autoclave Process
- Highest material quality: Excellent mechanical properties (high strength, stiffness, fatigue resistance). Very low porosity due to precise control of pressure and temperature.
- High reproducinility: Ideal for serial production of high-performance components with consistent quality.
- Precise control over fibre volume fraction: Prepregs contain a precisely defined amount of resin, optimizing the material properites.
- Optimal fibre orientation: Specific load cases can be accurately adjusted using targeted layup techniques.
- Minimal material waste: Compared to open resin processes, material loss is minimal.
Applications of the Prepreg Autoclave Processes
- Aerospace: Wing structures, fuselage structures, fairings, satellite components
- Automotive Industry (Motorsport & Luxury Vehicles): Monocoques, body parts, spoilers, lightweight components
- Medical Technology: Highly precise protheses, orthoses, and medical devices
- Sport and Leisure Industry: Bicycle frames, gold clubs, skis, tennis rackets
- Shipbuilding and Wind Power Industry: Lightweight structures for yachts and wind turbine blades
High strength with low weight
Maximum performance with minimal material usage, ideal for lightweight construction applications.
Customizable properties
The targeted combination of fibers and matrix materials allows mechanical, thermal, and chemical properties to be precisely tailored to specific requirements.
Corrosion-Resistance
Excellent resistance to environmental influences and chemicals, which extends the lifespan of components.
Design freedom
Enables the realization of complex geometries and innovative constructions that would be difficult to achieve with traditional materials.