Preventing surface defects and cracks in composite parts with sharp corners

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Fibre-reinforced composite materials are becoming increasingly promising as the material of today and the future in several products that are used on daily basis, from car/bicycle bodies to house appliances, among several other applications. The world market value of end-use products manufactured from composites was reported to be $55.6 billion in 2011-2012, with the North American composites industry accelerating at approximately 9%. A major focus and interest in this field is the development of value-added manufacturing processes that can further advance capabilities of these promising materials. The quality of final composite products, however, is closely linked to the accuracy of processing parameters applied during their manufacturing. Glass fibre reinforced plastics (GFRPs) are today the most common type of composites used in products fabricated through open moulding techniques, particularly since they offer low capital costs when compared to carbon fiber composites. One of the main metrics for quantifying the quality of a GFRP product is its surface finish. Inadequate choice of processing parameters can cause surface cracks and a non-uniform glossiness on the sharp corners of open-moulded parts, thereby requiring part repairs and extra costs before the parts can be assembled.