MATERIALS AND DESIGN, cilt.259, ss.1-13, 2025 (SCI-Expanded)
This study presents a novel strategy to overcome the limitations of
solid resin prepregs (SRPs) − namely the inability to drape at room
temperature and hindered gas evacuation during vacuum-bag-only (VBO)
processing − by 3D-printing a regular, uncured solid epoxy resin (SR)
pattern on a dry woven textile. The locally patterned resin distribution
preserves dry textile regions, enabling room temperature drapeability
and more robust VBO-processing due to improved gas evacuation. By
adjusting pattern parameters such as element geometry and coverage, the
draping behaviour can be controlled to adapt to a desired draping
condition. In order to be able to design the right pattern for given
draping conditions, the influence of these parameters on bending and
shearing was studied. Manual draping showed that bending radii down to
4 mm were achievable, governed only by the element length in bending
direction, while coverage had no significant effect. In contrast,
picture-frame-tests showed that the shearing is mainly influenced by the
coverage and that a maximal shearing angle of 30° can be achieved.
These results show that the SRPs bending and shearing can be
independently influenced through pattern design. The derived
structure–drapeability relationships enable targeted design of SRPs for
robust, autoclave-free composite manufacturing.