FLEXIBLE SILICONE MOLDS FOR THE RAPID MANUFACTURING OF ULTRA-THIN FIBER REINFORCED STRUCTURES.

Ultra-thin fiber reinforced structures with shell thicknesses below 100 μm are receiving increasing attention, mainly in the field of deployable satellite structures. These structures are prone to post-cure deformation, induced by residual stresses resulting from the cure. This study presents a novel manufacturing technique for quick and efficient prototyping of ultra-thin fiber reinforced structures fabricated from carbon fiber prepreg. The technique relies on sandwiching the composite layup in between silicone molds constrained by a metal cage. The molds are cast using 3D-printed molds. Thermal expansion inside the closed vessel can be used to pressurize the part, enabling an out-of-autoclave process. Several ultra-thin fiber reinforced parts have been manufactured and investigated with regard to their post-cure distortion by means of a noncontact measurement system, showing increased post-cure shape accuracy compared to conventional methods. Microscopic investigations of the shell thickness were performed, revealing sufficient pressure distribution over the part, making the process a promising manufacturing technique for the rapid prototyping of ultra-thin structures. [ABSTRACT FROM AUTHOR]