New Aerovac Films Enhance Composite Reliability in Vacuum Infusion

In the rapidly evolving field of composite manufacturing, companies continuously seek more efficient and reliable solutions to meet growing market demands and increasingly stringent quality standards. Vacuum infusion processing (VIP) has emerged as a proven method for producing high-quality composite components, widely adopted across aerospace, automotive, wind energy, and marine industries due to its superior performance and versatility.

The Critical Challenge: Demolding in Composite Manufacturing

Composite materials offer exceptional strength-to-weight ratios, corrosion resistance, and design flexibility, yet their manufacturing process presents unique challenges—particularly during demolding. This critical stage involves separating cured composite parts from their molds, where improper execution can lead to:

• Surface damage including scratches, tears, or deformation
• Premature mold wear or structural compromise
• Production delays and increased operational costs
• Higher rejection rates due to quality defects

Industry solutions have evolved to address these challenges, with release films emerging as the most effective method. These specialized films create a barrier between molds and composite parts, preventing resin adhesion while protecting both components and tooling.

Aerovac's Technological Edge in Release Films

Positioned at the core of vacuum infusion processes, Aerovac release films serve dual functions: facilitating clean part separation while preserving mold integrity. Engineered through advanced material science, these films deliver:

• Enhanced Production Efficiency: Significant reduction in demolding time through optimized release properties
• Surface Quality Assurance: Protection against cosmetic and structural surface defects
• Tooling Longevity: Prevention of resin contamination and chemical degradation of molds
• Application Versatility: Customizable solutions for diverse manufacturing requirements

Product Portfolio: Precision-Engineered Solutions

Perforated Release Films

Specifically designed for vacuum infusion processes, these films feature precision-engineered perforation patterns that regulate resin flow while ensuring consistent fiber impregnation. Available in multiple configurations including needle-punched, hot-needle, and stamped designs, each variant addresses distinct resin characteristics and processing parameters.

Non-Perforated Variants

Ideal for prepreg, hand lay-up, and wet lay-up applications, these solid films provide absolute resin containment with exceptional chemical and thermal resistance properties.

Specialty Films

For demanding applications, Aerovac offers engineered solutions including anti-static formulations for electronics manufacturing, flame-retardant options for aerospace applications, and high-elongation films for complex geometries.

Innovative Processing: The Infuply Breakthrough

Aerovac's patented Infuply technology represents a significant advancement by integrating release films with knitted flow media. This innovation delivers multiple benefits:

• 40-50% reduction in lay-up time through material consolidation
• Improved conformity to complex contours through memory-retentive knitted architecture
• Enhanced surface finish quality via optimized resin distribution
• Simplified post-cure removal without media residue

Particularly valuable in wind energy and marine applications, Infuply has demonstrated exceptional performance in manufacturing large-scale structural components with intricate geometries.

Customized Kit Solutions

• Precision-cut components reducing shop floor preparation time
• Standardized material usage ensuring process consistency
• Waste minimization through optimized material utilization
• Inventory simplification via ready-to-use packaged solutions

Industry Applications: Wind Turbine Blade Manufacturing

In wind energy applications, Aerovac solutions have demonstrated measurable improvements in blade production. One manufacturer reported a 30% reduction in lay-up time after adopting Infuply technology, coupled with a 15% decrease in material waste through customized kit implementation. The integrated approach maintained surface quality specifications while extending mold service life by approximately 20%.

Future Development Trajectory

• Development of next-generation materials with enhanced thermal and chemical resistance
• Optimization of perforation geometries for improved resin management
• Integration of smart functionalities for process monitoring and control
• Sustainable material formulations supporting environmental objectives

Through continuous innovation, Aerovac maintains its position at the forefront of composite manufacturing solutions, enabling manufacturers to achieve new levels of quality and efficiency in advanced material production.