Experimental investigation of thickness effects in the manufacture of thick-section composite structures using liquid thermoplastic resin

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Smith, Ione L. M. and McCarthy, Edward D. and Thies, Philipp R. and Oterkus, Selda and Obande, Winifred (2025) Experimental investigation of thickness effects in the manufacture of thick-section composite structures using liquid thermoplastic resin. Advanced Manufacturing: Polymer & Composites Science, 11 (1). 2521570. ISSN 2055-0359 (https://doi.org/10.1080/20550340.2025.2521570)

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Abstract

Thick-section composites (10–100 mm) are increasingly used in structurally demanding applications. Growing interest in sustainable alternatives has driven the development of recyclable, room-temperature-processable liquid thermoplastic resins to replace thermosets in vacuum-infused composites. However, managing the thermal effects of polymerisation to avoid boiling and defects remains a challenge in thick-laminate manufacturing . While low-exotherm grades are available, their behaviour in thick laminates remains poorly understood. This study examines the exothermic polymerisation of Elium® 188 XO, a low-exotherm thermoplastic resin, in laminates with thicknesses of 9.5 mm, 17.9 mm and 26.4 mm. Process times are presented to support implementation. Using five embedded thermocouples, maximum temperatures of 86.5°C, 92.6°C and 93.9°C were recorded, all remaining below the resin’s boiling point. The results indicate a progressive increase in interlaminar temperature with increasing laminate thickness. Ambient-temperature-adjusted data showed peak increases of 2.7°C and 3.1°C between successive laminate thicknesses. These findings provide critical insights into polymerisation behaviour, informing process optimisation and industrial adoption.

ORCID iDs

Smith, Ione L. M., McCarthy, Edward D., Thies, Philipp R., Oterkus, Selda ORCID logoORCID: https://orcid.org/0000-0003-0474-0279 and Obande, Winifred;
CORE (COnnecting REpositories)