Out-of-autoclave prepregs produce low-porosity parts through a complex consolidation process that includes air evacuation through a partially impregnated microstructure and subsequent resin infiltration flow. In this article, we propose, develop, and validate the first model describing this consolidation process by computing the thickness change of the material during processing. The air evacuation period is first simulated as a function of fiber packing and pressure conditions. Then, the cure period is described by modeling flow and compaction phenomena. Model predictions are compared to several experimental case studies, which show that the effect of most material properties and process parameters is well captured, and used in parametric studies to identify key trends.
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