PSI - Issue 66

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Mohammad Jameel Ziedan et al. / Procedia Structural Integrity 66 (2024) 229–246 Author name / Structural Integrity Procedia 00 (2024) 000–000

4. Conclusions This comprehensive review analyzes three key thermoforming methods for composite materials: Single Point Incremental Forming (SPIF), vacuum forming, and compression molding. The SPIF method excels in creating complex geometries with high precision, making it ideal for customized products and prototypes. However, its slower production speed may limit its suitability for large-scale manufacturing. In contrast, vacuum forming is a cost-effective process, suitable for the mass production of simpler parts. Its ability to form large sheets makes it particularly valuable in industries such as aerospace and automotive. The third method, compression molding, produces parts with excellent strength and durability, making it well-suited for high-demand applications. However, it requires high pressure and specialized molds, which can increase costs and complexity. This review also delves into specific aspects of each technique. For SPIF, process parameters, optimization methods, hole-flange forming, workpiece geometry, software tools, biocompatible polymers, and heating techniques have been explored. In vacuum forming, methods such as vacuum-assisted resin infusion molding, vacuum bag processing, and hybrid vacuum-forming techniques are reviewed. For compression molding, sheet molding compound (SMC) and injection molding methods are presented. It is essential to inspect all these composite manufacturing processes for cracks and voids, as these defects can significantly degrade mechanical properties. A thorough understanding of these forming techniques is crucial for engineers and designers working with composite materials. By carefully considering the advantages and limitations of each method, the most suitable process for producing high-quality composite components with desired geometries and properties can be selected. 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