Skip to main content
U.S. Department of Energy
Office of Scientific and Technical Information

Recent and future developments in pultrusion technology with consideration for curved geometries: A review

Journal Article · · Composites. Part B, Engineering

Herein this paper examined the current state and future developments in pultrusion with particular emphasis on its application in curved part manufacturing. The relationship between factors such as resin chemistry, fiber characteristics, and die geometry that influences the properties of pultruded product were highlighted. Moreover, the specific challenges associated with pultruding curved parts such as the complexities in achieving uniformity and structural integrity in such geometries were discussed. The review emphasized mold design, process improvement, adaptive control systems for precise resin impregnation and material selection to address these challenges. Additionally, the paper suggests the integration of real-time monitoring and data analytics as ways to enhance quality control during curved parts pultrusion. These advancements will help to overcome challenges specific to curved pultrusion and make the process more efficient. Other manufacturing techniques such as filament winding, thermoforming, pulforming were mentioned as alternatives to curved parts pultrusion. The review also explores pultruded variable curvature processes, highlighting some notable patents and article related to this subject matter. Production of pultruded variable curvature parts was seen as a key driver that can shape the future of pultrusion. Finally, the paper anticipates future trends, with sustainability, customization, integration of advanced materials, and development of techniques for pultrusion of composites parts.

Research Organization:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Grant/Contract Number:
AC05-00OR22725
OSTI ID:
2397444
Journal Information:
Composites. Part B, Engineering, Journal Name: Composites. Part B, Engineering Vol. 283; ISSN 1359-8368
Publisher:
ElsevierCopyright Statement
Country of Publication:
United States
Language:
English

References (96)

Simultaneous optimization of die‐heating and pull‐speed in pultrusion of thermosetting composites journal February 2003
Fiber reinforced nylon‐6 composites produced by the reaction injection pultrusion process journal October 1996
Effect of different fiber loadings and sizes on pultruded kenaf fiber reinforced unsaturated polyester composites journal April 2014
Fiber damage and impregnation during multi‐die vacuum assisted pultrusion of carbon/PEEK hybrid yarns journal February 2018
An overview on current manufacturing technologies: Processing continuous rovings impregnated with thermoset resin journal September 2021
Reaction injection pultrusion of thermoplastic and thermoset composites journal October 1995
An assessment on effect of process parameters on pull force during pultrusion journal June 2022
Effect of Resin Viscosity in Fiber Reinforcement Compaction in Resin Injection Pultrusion Process journal June 2013
Optimization of initiator and activator for reactive thermoplastic pultrusion journal January 2019
Real-Time Characterization of Pultrusion Processes with a Temperature Control journal May 2020
Pultrusion of a vertical axis wind turbine blade part-I: 3D thermo-chemical process simulation journal May 2014
Mechanical characterization of pultruded GFRP channel, wide flange and rectangular hollow profiles journal October 2021
Investigation of the influence of multiple thermoforming processes on the properties of continuous fiber-reinforced thermoplastics to enable structural reuse journal January 2023
Flexural properties of pultruded carbon/PEEK composites as a function of processing history journal September 1994
Orthogonal cutting mechanisms of graphite/epoxy composite. Part I: unidirectional laminate journal December 1995
Processing and properties of pultruded thermoplastic composites (I) journal September 1990
The impact of pultrusion processing parameters on resin pressure rise inside a tapered cylindrical die for glass-fibre/epoxy composites journal May 2000
Bent pultrusion—a method for the manufacture of pultrudate with controlled variation in curvature journal July 2003
Challenges for composites into the next millennium — a reinforcement perspective journal July 2001
Experimental and numerical study of the effect of cure cycle, tool surface, geometry, and lay-up on the dimensional fidelity of autoclave-processed composite parts journal March 2002
Investigation of the pressure behavior in a pultrusion die for graphite/epoxy composites journal September 1999
Role of sizing agent on the microstructure morphology and mechanical properties of mineral-impregnated carbon-fiber (MCF) reinforcement made with geopolymers journal November 2021
Manufacturing and mechanical properties of soy-based composites using pultrusion journal January 2004
Materials modelling and process simulation of the pultrusion of curved parts journal May 2021
Formation of non-uniform fibre distributions in winding-pultrusion process and its effect on axial compressive properties of hollow GFRP profiles journal October 2023
Optimising the energy consumption on pultrusion process journal February 2014
Material characterization of a polyester resin system for the pultrusion process journal August 2014
Investigation of process induced warpage for pultrusion of a rectangular hollow profile journal January 2015
Out of die ultraviolet cured pultrusion for automotive crash structures journal September 2015
Response of pultruded glass composite box beams under bending and shear journal March 2016
The effect of process parameters on ultraviolet cured out of die bent pultrusion process journal March 2016
A comprehensive review on mechanical properties of pultruded FRP composites subjected to long-term environmental effects journal June 2020
Material characterization of a pultrusion specific and highly reactive polyurethane resin system: Elastic modulus, rheology, and reaction kinetics journal February 2021
Steady-state modelling and analysis of process-induced stress and deformation in thermoset pultrusion processes journal July 2021
Pultrusion of large thermoplastic composite profiles up to Ø 40 mm from glass-fibre/PET commingled yarns journal December 2021
Thermoforming process effects on structural performance of carbon fiber reinforced thermoplastic composite parts through a manufacturing to response pathway journal April 2022
Cost-efficient, automated, and sustainable composite profile manufacture: A review of the state of the art, innovations, and future of pultrusion technologies journal November 2022
A model of multi-die thermoplastic pultrusion journal December 2022
Fibre volume fraction screening of pultruded carbon fibre reinforced polymer panels based on analysis of anisotropic ultrasonic sound velocity journal April 2023
Pultruded carbon fibre reinforced polymer strips produced with a novel bio-based thermoset polyester for structural strengthening journal March 2023
Testing and analysis of pultruded GFRP continuous beams for the deflection serviceability limit state journal May 2016
Bilinear softening model and double K fracture criterion for quasi-brittle fracture of pultruded FRP composites journal January 2017
Investigation of transverse residual stresses in a thick pultruded composite using digital image correlation with hole drilling journal September 2019
Effects of pulling speed on structural performance of L-shaped pultruded profiles journal January 2021
Developing an innovative curved-pultruded large-scale GFRP arch beam journal January 2021
Effects of high pulling speeds on mechanical properties and morphology of pultruded GFRP composite flat laminates journal December 2022
Effects of thermal expansion coefficients discrepancy on the CFRP and steel bonding journal February 2021
Mechanical Properties of Jute Spun Yarn/PLA Tubular Braided Composite by Pultrusion Molding journal January 2013
Mechanical properties of pultruded carbon fibre-reinforced polymer (CFRP) plates at elevated temperatures journal July 2011
Flexural performance of curved-pultruded GFRP arch beams subjected to varying boundary conditions journal June 2024
Biorenewable thermosetting copolymer based on soybean oil and eugenol journal August 2015
An integrated recycling approach for GFRP pultrusion wastes: recycling and reuse assessment into new composite materials using Fuzzy Boolean Nets journal March 2014
Thermoformable and recyclable CFRP pultruded profile manufactured from an epoxy vitrimer journal January 2021
Investigation on the Shape Distortions of Pultruded Profiles at Different Pulling Speed journal January 2020
Effect of Additives on Cure Kinetics of Pultrusion Resins journal January 2020
Progress and Trends in Damage Detection Methods, Maintenance, and Data-driven Monitoring of Wind Turbine Blades – A Review journal March 2023
Compressive behaviour of hollow box pultruded FRP columns with continuous-wound fibres journal November 2021
Pultruded Carbon Fiber/Vinyl Ester Composites Processed with Different Fiber Sizing Agents. Part I: Processing and Static Mechanical Performance journal June 2005
Pultruded Carbon Fiber/Vinyl Ester Composites Processed with Different Fiber Sizing Agents. Part III: Theoretical Aspects journal June 2005
Analysis of the local fiber volume fraction variation in pultrusion process conference January 2017
Short-beam shear fatigue behavior of round curved pultruded composite journal August 2021
Plant Fiber Reinforcements as Alternatives in Pultruded FRP Composites Manufacturing: A Review journal January 2024
Design and Implementation of Asymmetric Extrusion Die Using Bezier Technique journal July 2020
Multi-response optimization of the mechanical properties of pultruded glass fiber composite using optimized hybrid filler composition by the gray relation grade analysis journal November 2019
Computational Approaches for Modeling the Multiphysics in Pultrusion Process journal January 2013
Properties of natural fiber composites made by pultrusion process journal August 2011
Effect of water absorption on pultruded jute/glass fiber-reinforced unsaturated polyester hybrid composites journal September 2011
Influence of micro and nanofillers on mechanical properties of pultruded unidirectional glass fiber reinforced epoxy composite systems journal June 2015
Behaviour of hollow pultruded GFRP square beams with different shear span-to-depth ratios journal July 2016
A modified pultrusion process journal September 2016
Composite spirals and rings under flexural loading: Experimental and numerical analysis journal January 2020
Pultruded materials and structures: A review journal May 2020
On-site evaluation of a modified pultrusion process: Fibre spreading and resin injection-based impregnation journal July 2020
Effects of additives on the cure kinetics of vinyl ester pultrusion resins journal March 2021
Die-Less Forming of Large and Variable-Radii of Curvature in Continuous-Fiber Thermoplastic-Matrix Composite Materials journal April 1996
Pultrusion of Micro-Braided GF/PA6 Yarn journal November 1999
Innovating arch structures with fiber-reinforced polymer composites: A review journal June 2023
Influence of CaCO3 in pultruded glass fiber/unsaturated polyester resin composite on flexural creep behavior using conventional and time-temperature superposition principle methods journal November 2020
Processing and Evaluation of a Carbon Fiber Reinforced Composite Bar Using a Closed Impregnation Pultrusion System with Improved Production Speed journal May 2022
Imperfection Sensitivity Detection in Pultruded Columns Using Machine Learning and Synthetic Data journal April 2024
Mechanical Response and Fracture of Pultruded Carbon Fiber/Epoxy in Various Modes of Loading journal June 2022
Characterization Specifications for FRP Pultruded Materials: From Constituents to Pultruded Profiles journal November 2023
Proof of Concept for Pultrusion Control by Cure Monitoring Using Resonant Ultrasound Spectroscopy journal August 2020
Development of a Pultrusion Die for the Production of Thermoplastic Composite Filaments to Be Used in Additive Manufacture journal May 2021
Pultruded GFRP Reinforcing Bars Using Nanomodified Vinyl Ester journal December 2020
PPESK-Modified Multi-Functional Epoxy Resin and Its Application to the Pultrusion of Carbon Fiber journal September 2018
Thermoplastic Pultrusion: A Review journal January 2021
Numerical Simulation of Impregnation Process of Reactive Injection Pultrusion for Glass Fiber/PA6 Composites journal February 2022
Prediction of Fracture Toughness of Pultruded Composites Based on Supervised Machine Learning journal September 2022
Different Production Processes for Thermoplastic Composite Materials: Sustainability versus Mechanical Properties and Processes Parameter journal January 2023
Effects of Additives on the Mechanical and Fire Resistance Properties of Pultruded Composites journal August 2023
Characterisation of Curing of Vinyl Ester Resin in an Industrial Pultrusion Process: Influence of Die Temperature journal September 2023
Effects of Process Parameters in Thermoforming of Unidirectional Fibre-Reinforced Thermoplastics journal January 2024
Pulse Ultrasonic Cure Monitoring of the Pultrusion Process journal October 2018
Bio-Pultrusion of Façade-Profiles from Sustainable Materials journal July 2015
The resistance to UV radiation for GFRP pultruded bridge panels journal July 2022

Figures / Tables (16)


Similar Records

Analysis of pultrusion processing for long fiber reinforced thermoplastic composite system
Technical Report · Sun Oct 31 23:00:00 EST 1993 · OSTI ID:5438340

Experimental simulation of the thermoplastic pultrusion process
Conference · Mon Dec 30 23:00:00 EST 1996 · OSTI ID:412103

In-line powder coating of pultrusions
Conference · Thu Oct 31 23:00:00 EST 1996 · OSTI ID:392417