Zero-waste prepreg production through the combination of automated fiber Placement and Online-Prepreg Technology

In recent years, automation in the composites industry has transformed production, enabling precise, cost-effective lay-ups and expanding the applications of once-expensive high-performance materials. Automated Fiber Placement (AFP) is one such technology that uses dry spread tapes to customize fiber orientations and achieve exceptional mechanical performance while minimizing waste. However, conventional resin infusion methods face challenges with such preforms, prompting the exploration of alternatives such as online-prepreg (OPP) technology. OPP streamlines the automated production of prepreg semi-finished products from dry fiber textiles, reducing resin-contaminated waste and improving recyclability. This study proposes the combination of AFP and OPP to achieve near-zero waste pre-impregnated preforms. Dry preform lay-ups with different binder contents and fiber orientations were prepared using AFP before transfer to the OPP setup. Optimization of resin application ensured uniform distribution over the desired fiber volume content. The resulting prepregs were cured for subsequent analysis. Mechanical properties of the resulting samples were evaluated for interlaminar strength using both standard experimental and simulation methods, while optical microscopy was used to examine various laminate sections for entrapped air bubbles. CT scan models were examined for contamination and to determine the directionality of the fiber lay-ups. Finally, the environmental impact of such a manufacturing process was briefly discussed.