Introduction:

The increasing application of CFRP and GFRP components in structural elements requires
economically improved production processes for composite parts which fulfil highest
productivity and quality requirements.
Composite materials are used for the propeller blades of Voith Contur Propellers and Voith
Inline Thrusters.

With these materials, the mass of the blades decreases and the vibration and damping
characteristics greatly improves, compared to conventional bronze blades. Furthermore, the
hydroelastic properties can be exploited to improve the efficiency in several load cases.
The marine propeller is manufactured in a compression molding process. The advantage of
the compression molding is the high geometrical precision and reproducibility of the
composite part.
Additionally it is possible to avoid undesirably inclusions of air or foreign sub stances in the
matrix material. During the manu facturing process the excessive epoxy resin is pressed
through the prepregs out of the tool, so that a uniform resin distribution without inclusions is
guaranteed.

Step-by-Step Process of Compression Molding for a Composite Marine Propeller

Compression molding is a widely used manufacturing technique for producing high-strength
composite components, including marine propellers. It involves applying heat and pressure to
shape the composite material into the desired form. Here’s a step-by-step breakdown:
1. Mold Preparation:
 Design & Fabrication: A two-part mold (male and female) is designed based
on the propeller's geometry, typically made from steel or aluminum.
 Surface Treatment: The mold is coated with a release agent (e.g., wax or
Teflon-based sprays) to prevent the composite from sticking.
 Preheating: The mold is heated to the required temperature (typically 150–
250°C, depending on the resin system).
2. Material Preparation:
 Fiber Selection: The composite propeller is typically made from carbon fiber
or glass fiber-reinforced polymers (CFRP/GFRP) for strength and corrosion
resistance.
 Resin Selection: A thermoset resin (e.g., epoxy, polyester, or vinyl ester) is
chosen for binding the fibers.
 Prepreg Preparation: If using prepregs (fiber sheets pre-impregnated with
resin), they are cut into precise shapes to fit the mold.
 Stacking Layers: Multiple layers of fiber are stacked in the mold according to
the required fiber orientation (e.g., 0°, 45°, 90°) to optimize strength and
stiffness.

3. Compression Molding Process

 Placing Material in the Mold: The fiber sheets or prepreg materials are
carefully placed inside the heated mold.
 Closing the Mold: The mold is closed with high precision to align the top and
bottom halves perfectly.
 Applying Pressure: A hydraulic press applies pressure (typically 5–50 MPa,
depending on material thickness). This ensures uniform resin distribution and
eliminates air voids.
 Curing Process: Heat and pressure activate the resin’s polymerization,
solidifying the composite structure. This step can take 30 minutes to several
hours, depending on the resin system.

4. Cooling & Demolding:

 Cooling Down: The mold is gradually cooled to prevent thermal stress or
warping.
 Releasing the Propeller: Once the resin is fully cured, the mold is carefully
opened, and the composite propeller is removed.

5. Finishing & Quality Control:

 Trimming & Machining: Excess material is trimmed, and edges are
smoothed using CNC machining or grinding.
 Surface Treatment: The propeller may undergo sanding and coating for
additional UV and water resistance.
 Structural Testing: The propeller is tested for defects (e.g., ultrasonic testing,
X-ray inspection) and performance evaluation.
1. Placing Fiber in the Mold
There are two primary ways to place fibers into the mold:

A. Using Prepregs (Pre-Impregnated Fibers) – Recommended for High

Precision
 Prepregs are composite sheets where fibers are already impregnated with
resin in a controlled ratio.
 Cut the prepreg sheets into required shapes based on the mold design.
 Lay the sheets into the mold one by one, following the required fiber
orientation (e.g., 0°, ±45°, 90°).
 Ensure proper stacking sequence to achieve the desired mechanical
properties.
 Apply pressure and heat in a compression molding machine to cure the
resin.

B. Using Dry Fibers & Infusing Resin – More Customizable

 If using dry carbon/glass fibers, it need to apply resin separately:
 Cut dry fiber sheets (woven or unidirectional) to match the mold shape.
 Place them into the mold, arranging layers with the required fiber
orientations.
 Use Vacuum-Assisted Resin Transfer Molding (VARTM) or Resin
Infusion:
o Seal the mold and apply vacuum to remove air.
o Inject resin, ensuring full saturation of fibers.
o Apply heat to cure the resin and harden the structure.

2. Binding Fibers with Resin

Resin acts as a binding agent to hold fibers together and transfer loads between them.
Two primary methods:
 1. Prepreg Method: Fibers are already impregnated with resin; just need to apply heat
and pressure.
2. Wet Lay-Up Method: Resin is applied manually or injected into dry fibers inside the
mold.

Curing:

 Resin hardens at elevated temperatures (e.g., 120°C–180°C for epoxy).

 Pressure ensures proper fiber compaction and removes air voids.

3. Applying Fiber Orientation

Fiber orientation is crucial for controlling strength and stiffness. Can lay fibers:

By Lamina (Layer-by-Layer) – This is the standard approach. Each lamina consists

of a single fiber orientation. Example:

0° → Load-bearing strength in the main direction.

±45° → Shear strength improvement.
90° → Prevents splitting in the transverse direction.

By Random Fiber Placement – Not recommended for structural parts like

propellers.

Layer Orientation Purpose

1st layer 0° (Chordwise) Main load-bearing
2nd layer ±45° (Shear) Shear strength & torsion
resistance
3rd layer 90° (Spanwise) Prevents splitting
4th layer 0° (Chordwise) Strengthens leading edge

Resin Transfer Molding (RTM) – Best for Mass Production

RTM is a closed-mold process where dry fiber reinforcements are placed inside a mold, and
resin is injected under pressure to form a strong composite part.
Step-by-Step Process:
1. Mold Preparation
o A two-part closed mold (metal or composite) is cleaned and coated with a
release agent to prevent resin sticking.
o Heating elements may be embedded in the mold for curing.
2. Placing Fiber Preforms
o Dry fiber pre-cut sheets (carbon or glass fiber) are layered inside the mold.
o The fiber orientation follows the required layup schedule (0°, ±45°, 90°).
3. Mold Closing & Clamping
o The upper mold is closed tightly to avoid leaks.
 o A vacuum may be applied inside the mold to help with fiber compaction.

4. Resin Injection
o Liquid thermosetting resin (epoxy, polyester, or vinyl ester) is injected under
pressure (2-10 bar).
o The resin flows through the fibers, ensuring full saturation.
5. Curing Process
o The mold is heated (typically 80–150°C) to cure the resin.
o Curing time varies (1–4 hours) depending on the resin type.
6. Demolding & Finishing
o Once cured, the propeller is removed from the mold.
o Edges are trimmed, sanded, and polished for final finishing.
Pros & Cons
✅ Advantages:
o High precision and consistency in quality.
o Good surface finish with minimal post-processing.
o Suitable for medium-to-large-scale production.
❌ Disadvantages:
o High mold cost, making it expensive for low-volume production.
o Requires complex injection systems.

Vacuum-Assisted Resin Transfer Molding (VARTM) – Best for Large Propellers

VARTM is similar to RTM but uses a flexible vacuum bag instead of a rigid upper mold. It’s
ideal for large composite propellers.
Step-by-Step Process:
1. Mold Preparation
o A single-sided mold is coated with a release agent.
o Dry fiber pre-cut layers are placed into the mold following the layup schedule.
2. Placing Vacuum Bag & Sealant
o A vacuum bag (flexible plastic film) is placed over the fibers and sealed with tacky
tape.
o Vacuum ports are attached to remove air.
3. Applying Vacuum
o A vacuum pump is connected, removing air and compressing the fibers.
o This step ensures proper compaction before resin is introduced.
4. Resin Infusion
o Resin is drawn into the mold by vacuum suction, flowing through the fibers.
o Flow rate is carefully controlled to ensure full saturation.
5. Curing
 o The propeller is left to cure at room temperature or inside an oven (typically 24 hours
at 25–50°C)

6. Demolding & Finishing

o The cured part is removed, and excess material is trimmed and polished.

Pros & Cons

✅ Advantages:
o Less expensive than RTM (no high-pressure equipment needed).
o Can be used for very large marine propellers.
o Good fiber-to-resin ratio → higher strength.
❌ Disadvantages:
o Slower process compared to RTM.
o Risk of uneven resin distribution.

Filament Winding – Best for Propeller Shafts & Curved Surfaces

Filament winding is an automated method where fibers are wound around a rotating mandrel
to create hollow or curved composite parts.
Step-by-Step Process:
1. Mandrel Preparation
o A mandrel (mold) in the shape of the propeller blade or shaft is placed inside the
winding machine.
2. Fiber Winding
o Continuous fiber tows (carbon or glass) are dipped in resin.
o Fibers are wound around the mandrel in predefined angles (e.g., ±45°, 90°).
3. Curing Process
o The wound mandrel is placed in an oven (120–180°C) for curing.
o After curing, the mandrel is removed, leaving a hollow composite structure.
4. Finishing
o The propeller is trimmed and polished for final shape.

Pros & Cons

✅ Advantages:
o Produces high-strength, lightweight parts.
o Automated process → high precision and repeatability.
❌ Disadvantages:
 o Limited to cylindrical and curved shapes.
o Expensive filament winding machines needed.

Hand Lay-Up – Best for Custom Prototypes & Small-Scale Production

The simplest method, where fibers are manually placed in a mold and resin is applied by
hand.
Step-by-Step Process:
1. Mold Preparation
o A mold is coated with a release agent to prevent sticking.
2. Layering Fibers
o Dry fiber sheets are manually placed layer by layer.
o Orientation is adjusted (0°, ±45°, 90°) as per design.
3. Applying Resin
o Resin is brushed or rolled onto each layer.
o A roller is used to remove air bubbles and ensure saturation.
4. Curing Process
o The part is left to cure at room temperature (24–48 hours) or inside an oven.
5. Demolding & Finishing
o The propeller is removed, and excess material is trimmed and polished.

Pros & Cons

✅ Advantages:
o Low-cost method (good for prototyping).
o Allows custom fiber orientation.
❌ Disadvantages:
o Labor-intensive & slow.
o Higher chances of defects (air bubbles, weak spots).

Additive Manufacturing (3D Printing + Composite Infusion) – Future Technology

A combination of 3D printing and resin infusion to create highly customized composite
propellers.
Step-by-Step Process:
1. 3D Printing the Core or Mold
o A plastic or metal mold is printed using 3D printers.
2. Fiber Placement
o Carbon or glass fibers are placed onto the 3D-printed structure.
3. Resin Infusion & Curing
 o Resin is infused using VARTM or manual lay-up.
o The part is cured in an oven or autoclave.
4. Final Finishing
o The final propeller is trimmed, polished, and tested.

Pros & Cons

✅ Advantages:
o Allows complex geometries.
o Good for rapid prototyping.
❌ Disadvantages:
o Still expensive for large-scale production.
o Limited by current 3D printing technology.