Development of vacuum-assisted prepreg compression molding for production of automotive roof panels

Prepreg compression molding (PCM) is well known for its high productivity among the manufacturing processes for carbon fiber reinforced plastic (CFRP) products. However, the disadvantages of CFRP products manufactured by the PCM process are related to defects involving micro grooves and voids. The purpose of this study is to develop a vacuum-assisted prepreg compression molding (VA-PCM) process to prevent these defects. To verify the application of the VA-PCM process, the mechanical properties of small-scaled specimens fabricated by the VA-PCM process were compared with the mechanical properties of specimens fabricated by the PCM process. The tests related to surface roughness, void content, tensile, and three-point bending were performed to evaluate the mechanical properties, including elastic modulus, tensile strength, bending stiffness, and energy absorption. Finally, automotive roof panels produced by each process were evaluated by a bending test to validate the VA-PCM process.