Surface quality management of GFRP moulds during composite manufacturing cycles

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Fibre-reinforced composite materials are becoming increasingly promising as the material of today and the future in leading industries such as aerospace, transportation and construction. A major focus in the field is the development of value-added manufacturing processes that can further advance capabilities of these promising materials. The quality of final products composite made of composites, however, is closely linked to the quality of the tools used during manufacturing. Glass fibre reinforced plastics (GFRPs) are today the most common materials used for composite moulds, particularly since they offer low capital costs when compared to their metallic counterparts. The GFRP moulds typically have a lifespan of 200-500 manufacturing cycles and manufactures are required to carefully manage the quality of moulds during all usage and storage phases. One of the main metrics for quantifying the quality of a GFRP tool is its surface roughness, since it can directly affect the friction state and adhesion to the corresponding part during moulding and de-moulding operations. Specifically, having a high surface roughness on a mould can cause small-scale wrinkles and micro-cracks on the associated part surfaces, thereby requiring part repairs and incurring extra manufacturing costs.