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ME-542 Manufacturing with Non-metallic MaterialsLay-up of a 90/45/-45/90 panel from a no-bleed, vacuum curable prepreg.
Prepreg layup:
Needed: Prepreg, vacuum coffin, release cloth, breather cloth, scissors, gloves, polyethylene film
Obtain a roll of 12" wide unidirectional 0° prepreg from the freezer
Cut two 12" long pieces from the roll
Use the 45° template to cut a few rhombic ply segments from the prepreg as demonstrated.
Construct 45° ply segments as demonstrated.
Return the roll to the freezer
Cut a layer of polyethylene film large enough to wrap a 12" x 12" panel in and place it on a flat surface.
Lay the first piece of prepreg (lamina) with one backing film intact against the plastic film and remove the second release film to expose the surface of the prepreg.
Remove the backing film from one side of the next lamina segements and place this side so that the fibers are at 45° to the exposed lamina already in place. Carefully press the two together with gloved hands and work any air bubbles to the edges. If the layer wrinkles or splits, try again or cut another layer. Once the layer is in place, remove the second exposed backing film layer from the top of the 2 layer stack.
Remove the backing film from one side of the next lamina and place this side down at 90° to the ply orientation of the exposed lamina already in place. Remove the second exposed backing film layer from the top of the 3 layer stack.
Remove the backing film from one side of the next lamina and place this side down but in the same orientation as the first lamina. Remove the second exposed backing film layer from the top of the 4 layer stack.
Flip the 4 layer laminate over and remove the backing film on the (now) top of the stack.
Wrap the laminate in the plastic film, tag it with your name, and place it in the freezer.
Processing:
Apply two coats of FreeCoat liquid release to the inside metal surface of the vacuum coffin using a paper towel.
Cut and place a layer of release cloth on the inside of the vacuum coffin. Place the laminate on the release cloth after removing the plastic wrap.
Cut another layer of release cloth and then cover the laminate with it and a layer of polyester breather cloth large enough to reach the corners adjacent to the vacuum ports in the top of the coffin. Seal the coffin and draw a vacuum for 2 minutes. Disconnect the vacuum source.
Preheat the lower press platen to 250°F and place the coffin on the lower platen. Reconnect vacuum and wait 30 minutes. Remove and cool coffin. Remove laminate and save release and breather cloth for reuse.