Polymer film dewetting for fabrication of out-of-autoclave prepreg with high through-thickness permeability

Polymer film dewetting on a substrate (independent of fiber bed architecture) was explored, developed, and demonstrated as a method to produce out-of-autoclave, vacuum bag-only (OoA/VBO) prepregs with high transverse permeability and process robustness. The dimensions of the surface openings created by dewetting were measured,and thepercent surface area exposed was calculated. Prepregs were fabricated with continuous and dewetted (discontinuous) films to producetrial laminates. The laminates were cured under both standard and sub-optimal conditions, and were characterized before, during, and after cure.Laminates fabricated with dewetted resin consistentlyachieved near-zero porosity. In contrast,laminates with continuous filmdisplayed high levels of porosity,particularly during sub-optimal cure. The findings demonstrate that dewetting can be used effectively to produce OoA prepregs with high through-thickness permeability, whichcan yieldporosity-free laminates via VBO processing. Furthermore, these results elucidate aspects of resin dewetting that are critical in thecreation ofrobust OoA prepregs.