Narrow flake composite fiber material compression molding

摘要

Methods provide for creating a three-dimensional random fiber orientation in a composite component. According to embodiments described herein, narrow flakes (304) are created from a unidirectional composite fiber tape and poured into a reservoir of a mold (202), creating a three-dimensional random fiber orientation of the narrow flakes within the reservoir. At least a majority of the narrow flakes have an aspect ratio of length to width of at least 6:1. The narrow flakes are heated and compressed to fill the mold and create the composite component. The three-dimensional random fiber orientation of the narrow flakes within the reservoir is maintained as the narrow flakes are pushed through the mold, creating consistent, uniform strength characteristics throughout the resulting composite component.