Optimization of the VARTM Process for Prototyping a Bumper Using Hybrid Composite Materials

Abstract

To provide an alternative for manufacturing auto parts using composite materials, the Vacuum Assisted Resin Transfer Molding (VARTM) process was utilized to prototype the bumper for the Chevrolet Aveo vehicle. This technique emerges as an alternative for composite material manufacturing, allowing for rapid and high-quality production of advanced composites. In this study, a hybrid composite material reinforced with fiberglass, cabuya fiber, IN2 epoxy resin, an infusion mesh, peel ply, and a vacuum bag was employed. To optimize the VARTM process in bumper prototyping, several simulations of resin flow were conducted with different locations of resin injection and vacuum entry points. Autodesk Moldflow Insight software facilitated the modification and addition of resin injection points to observe the flow evolution, thus determining the filling time for each proposed design. Six different designs were applied for the bumper mold filling. The proposed linear flow design reduced the total filling time of the bumper mold by 81.56% compared to the other five designs analyzed. The result of the numerical simulation was validated through the experimental process, where a high degree of concordance in the mold filling time was achieved between both methods.