TechNotes.

TECHNICAL INFORMATION BULLETIN

PUBLISHED BY RESOLTECH SARL2003

INFUSION
TECHNOLOGY

Infusion will see an exponential development in the years 2000, fuelled by new
regulations to reduce the amount of solvents and VOC in the environment and
the need to mould large composite structures in one operation.
The principle is simple: apply all the reinforcements and cores in a mould, then
bag it and start infusing a low viscosity matrix polymer through the whole layup.
The reality is a bit more complex: how to make sure the infusion process will
work as planned? How to ensure full wet out without dry patches? Will the resin
travel above and below the core the same way?
A comprehensive range of materials, solutions and services for the manufacture
of large composite parts by infusion
moulding.
A BIT OF HISTORY
Infusion is not quite a new process. The
first attempts to inject resin into a closed
mould occurred in the 1950s, namely by
Muskat who created a system called the
Marco Method. In 1967, Muskat patented
RTM (Resin Transfer Moulding). The
process saw industrial use by Lotus
Group in the manufacture of low volume
car parts in 1972. The next big step was
in 1990 when Palmer and then Seeman
developed the SCRIMP system. SCRIMP
is based on using a net over the laminate
to let the resin circulate. Since then,
KIS: Simulation and application.

other systems have appeared, with

or without net. To name a few: KIS
(Kaizen Infusion System), VEC
(Virtual Engineered Composites),
Light-RTM, as well as dozens of
indigenous techniques developed
by users themselves and not advertised.
Thousands of manufacturers worldwide are considering infusion for
the near future.

WHAT IS INFUSION?
Infusion is extremely competitive for the manufacture of low volume, very large structures with a high reinforcement ratio. It is also very well suited to the development of
prototypes to be manufactured under RTM/injection once in volume production.
The process is basically to inject a low viscosity resin under vacuum into a laminate.
The whole layup is installed first into a mould fitted with a rather simple vacuum bag.
Applying vacuum to the layup will compact the fibre reinforcements and allow for the
operators to check for air leaks. The pre-mixed resin is then allowed to migrate through
the layup until the whole part is wetted out.
Different techniques show some variations, mostly in the resin-transfer medium (net,
line, central or peripherical supply, etc).
PROBLEM LINKED TO THE INFUSION PROCESS
Many talk about infusion but few have actually experienced the process. While the idea
may be very simple, the application is based on very complex theoretical principles.
Infusion relies on two physical phenomenons: permeability and pressure difference.
Should the reinforcement not be porous or the pressure be even, there would be no
resin migration. These aspects are quite difficult to simulate or work out without wasting time, materials and money.
Permeability of the reinforcements is critical. It is twofold: macroscopic permeability
(the space between fibres allowing the resin to flow) and microscopic permeability (also
called capillarity).
Macroscopic permeability varies with the compression of the reinforcing fabrics. Microscopic permeability or capillarity follows the surface tension of the resin system. A high
surface tension of the matrix system will reduce the impregnation of fibres by capillarity while a low tension increases the capillarity effect.
Resin viscosity is also very important. The lower the viscosity, the faster the infusion
will occur.
Other parameters include thixotropy, fibres sizing, mould permeability & core properties.
PRACTICAL ASPECTS
The most widely used infusion process today is SCRIMP, as it has been the longest on
the market. It relies on a surface net applied onto the laminate to circulate the matrix
system. The resin circulates quickly on the surface and then saturates the laminate
throughout its thickness. SCRIMP generates a fairly high quantity of waste, as the net,
peel ply and cured resin will be thrown away at the end of the process.
KIS does not require a net to circulate the matrix, therefore also saving the peelply and
any cured resin wasted with these two layers. It does require specific reinforcements
and low viscosity resin systems to allow for the migration process through the laminate .
WHICH MATERIALS TO USE?
Most reinforcing fabrics are suitable. They include woven fabrics, unidirectional and
multiaxial products in glass, aramid, carbon and also hybrid versions.
Ordinary Chopped Strand Mat is not suitable since it requires styrene to be moulded.
Polyester, vinylester and epoxy resins are commonly used. They need to have adapted
viscosity.
Resoltech has formulated several epoxy and vinylester resin systems for infusion, including the 1800, an epoxy system witrh an extremely low viscosity of 160mPas.
Polyester resins can generate problems such as boiling when under vacuum; this can
also occur with vinylester systems, although less. Epoxy systems do not present this

type of problem.
The vacuum bag film will have to be carefully selected to withstand the parameters of
the infusion process, mainly temperature as some matrix systems will generate a certain amount of heat while curing, or require an elevated temperature post cure.
Most core materials can be used, as long as they stand the temperature involved.
PREPARATION
It is critical to ensure total airtightness of the mould/
bag combination. It will therefore be important to work
in a clean environment and avoid loose fibres and other
products to contaminate the moulsd edges where the
seal will be fitted. It is basically the same process as
using a vacuum bag over a wet or prepreg layup.
The reinforcing fibres are laid dry, so are the cores. It
is important to work carefully and avoid any voids
which would channel the resin.
THE INFUSION PROCESS
Different strategies are possible. The most common
solution is to divide the area and engineer a network of
resin lines interlaced with vacuum lines.
Infusion at Lagoon Catamarans, France
Another solution is to fit the resin lines with a main line
installed centrally and several smaller lines connected to it (similar to a fish squeletton). The vacuum points are then installed on the edges of the mould.
It is also possible to fit the resin lines around the mould and install several vacuum
points onto the bag.
THE RISKS INVOLVED
The first risk is to waste much time and materials in R&D, by using a trial and error
process. This can be avoided by computer simulation.
A non-controlled infusion process can lead to dry patches and air entrapment in the
laminate. The infusion process will tend to generate channels where the resin will flow
faster than through the reinforcement. Basically, the resin will always favour easier
ways to flow over low permeability areas. This can generate dry patches.
Air bubbles can also occur, mostly if the mould/bag combination is not totally sealed.
Another possible problem is resin boiling, due to a wrong vacuum adjustment.
THE KAIZEN INFUSION SYSTEM
Kaizen Technologies Inc of Montreal, Canada, has developed an infusion process, called
KIS for Kaizen Infusion System. This process is based on the use of optimized reinforcements and resin systems and does not require a circulation net. This has the advantage of saving on costs and waste.
Another advantage of the KIS is a computer simulation package that tells you what will
happen in the mould without going through the painful process of trial & error.
SIMULATION
Kaizen Technologies will run your laminate on their computers and simulate with great
accuracy the whole infusion process. This is utterly cost effective as well as being reassuring. Manufacturers can forecast and compare infusion with other solutions.

THE KIS PROCESS

He best way to optimise the benefits of the KIS process is to use specific reinforcements with optimised permeability together with low viscosity resin systems.
In addition to the choice of materials, Kaizen Technologies also supplies a self-releasing
vacuum bag, thus eliminating wastes and extra costs. An even better alternative for
production is a reusable silicon bag.
The KIS process will allow several infusion/vacuum arrangements, although the process
Is optimised with the use of peripherical infusion points and vacuum points fitted on the
bag.
THE RESOLTECH INFUSION SOLUTIONS
Resoltech has been working with infusion developers including Kaizen Technologies Inc
to provide a range of resin systems optimised for infusion.
RESOLTECH 1800
Probably the best infusion epoxy system available. Extremely low viscosity (160mPas),
long infusion time (5H30mn), flat viscosity curve right until the start of the curing process, TG up to 130C.
RESOLTECH 1050
Another epoxy system with excellent general properties.
RESOLTECH 5050 VI
A vinylester infusion system providing excellent thermal and chemical resistance.
REINFORCEMENTS
A range of reinforcements with controlled porosity has been developed by Kaizen Technologies to be used with the KIS process.
For other infusion solutions, a large number of standard reinforcements is available.
CONTACT DETAILS
For more information or to get started with the infusion process, Resoltech offers technical advice, computer simulation, materials and systems.

NOTICE. Due to its policy of continual development and improvement, Resoltech reserves the right to alter
specifications and prices without prior notice. Any information is given in good faith, based on test results and
believed to be accurate, and intended for use by customers at their own risks.

ILLUSTRATIONS COPYRIGHTS
Courtesy of Kaizen Technologies Inc, Canada, Lagoon Catamarans, France and Resoltech, France.

resolving your engineering challenges

RESOLTECH SARL
35 Impasse Emeri. ZI Les Jalassieres. 13510 Eguilles. France
Tel: (+33) (0)442 95 01 95 Fax: (+33) (0)442 95 01 98

www.resoltech.com export @ resoltech.com

TechNotes2/02-03