Vacuum bag-only prepregs enable the out-of-autoclave manufacture of high-performance composite structures and increase the material, part, and process selection space. However, manufacturing choices involve economic as well as technical considerations. To understand these relationships, we developed a technical cost model that captures the distinctive characteristics of vacuum bag-only prepreg processing (including vacuum-induced air evacuation and resin cure) and estimates the costs associated with materials, equipment, and labor. We applied the model to realistic manufacturing cases and used a parametric study to evaluate the effects of part characteristics, material use efficiency, and cure efficiency. The results indicate that prepreg cost, part size, prepreg waste, and the air evacuation capacity of the material have the strongest influence on part costs and demonstrate that cost modeling can guide efforts to improve or optimize processing by identifying the most economically valuable modifications.
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