Abstract

Developments of technical textile fibres continued to play an important role in diversifying its application arenas including the inception of advanced composite materials (ACM) using engineered fibres like glass, aramid, and carbon. The aerospace industries have significantly increased the use of ACM due to few factors like higher production rate comparing to unidirectional laminate elements, superior strength to weight ratio over traditional materials (such as metals or ceramics) and enhanced structural stability from interwoven/interlacement of yarns. Automotive and marine industries are also embracing the use of ACM due to its improved tolerance to cut or physical damage. ACM encompasses a wide variety of fabrication model and manual lay-up is the simplest of all. However, there is a knowledge gap among textile academia regarding the hand lay-up model and the science behind it, which is addressed in this case study. To benefit the academia with the knowledge of current aerospace industrial practice, a manual has been prepared in this case study routing the step by step fabrication model with its corresponding schematics and digital imaging during the production protocols of an industrial aircraft composite sandwich panel by using honeycomb aramid core with prepegs (made of technical textile fibres) like graphite and glass fibres.

Keywords: Aircraft panel; Prepeg; Glass fibre; Graphite fibre; Carbon fibre; Aramid; Composite; Honeycomb sandwich; Lay-up; Fabrication; Composite fabrication; Fibre reinforcement; Technical fibre