Compression Molding of Carbon Composite Prosthetic Foot Blade

Abstract

The objective of this master project is to inspect the possibility of compression molding carbon composite foot blades. A proven method was selected from the literature, the method was chosen due to its usage for compression molding composites with curved surfaces where an elastic medium is used as an interface between the solid mold halve and a laminate.Two different test cases were created to compare appearance, strength and stiffness of compression molded samples to autoclave cured samples. The result of this comparison showed that toe stiffness of samples varied by less than 4.5% while static strength of compression molded samples was considerably lower. Appearance of samples was deemed comparable.Conclusion of the project was that the chosen method was not ideal for compression molding carbon composite foot blades due to loss of resin during the compression molding resulting in weak and brittle foot blades during static loading. An alternative method is suggested. It has the perceived benefit of providing a more controlled mold cavity and a more even pressure distribution on the laminate.