Preform developments for resin infusion for rapid high-performance molding (RAPM) for small parts

Resin infusion was one of three forming processes evaluated in the RApid high-Performance Molding (RAPM) for Small Parts program performed under the DARPA Tailorable Feedstock and Forming (TFF) initiative. As part of this study, key features and processing parameters necessary for the successful processing of fibrous preforms for complex, aerospace-relevant part geometries were developed. The work herein describes the fabrication trials performed within RAPM to identify preforming design guidelines to ensure good part quality. Some of the details of the trials will be provided along with photomicrographs and other data to show how the various preforming materials and process parameters affected part quality. A summary of the findings to date will also be provided. Although commercial modeling tools exist for the characterization of forming preforms to complex geometries, they still require characterization of the building-block preform materials as well as validation versus real-world examples. Below, work in developing tools and guidelines for forming complex-shaped preforms with relatively high degrees of difficulty is discussed. These results can be used in the future to help create better modeling tools to shorten the development time necessary for developing preform-handling and -forming protocols as well as the physical tools necessary to create them.