Development of a Resin Infusion Technique for the Manufacture of Personal Watercraft

Abstract

The research outlined in this Masters of Engineering thesis represents an investigation into the use of a resin infusion process in the production system of BoardCo, a manufacturer of windsurf, surf, and stand up paddle boards. This study focused on both the practicalities of using resin infusion with the current set of materials, and the commercial viability of using resin infusion in place of the current hand lamination process. From the current BoardCo production process a set of materials were identified and characterised for use in a resin infusion process. RC203 carbon fibre and K618HET glass fibre reinforcements were tested for compaction and permeability response. M80 corecell foam, 16kg/m³ and 28kg/m³ EPS foam were tested for compaction response, thermal stability, and resin compatibility. An infusion process was established for the selected materials, including a number of key modifications to the standard resin infusion process to allow for the use of a low density EPS core. The SimLCM simulation software package was used to determine the resin distribution layout with the aim of optimising channel placement for minimal added mass within the required fill time. A cost model was developed to determine the marginal production cost per board based on both the required materials and labour time. This model was applied to a range of production techniques, identifying areas of possible reduction in labour or materials costs for different resin infusion processes. It was identified that the use of a resin infusion process could reduce required labour time and overall production time by 25- 30% A recommended resin infusion process for use in the BoardCo production system was outlined based on the developed practical and commercial understanding. This process can be used to produce parts with four laminates in a single process stage. It was found that when resin is prevented from entering the EPS core a high quality part is produced.