Sandwich structures utilize the geometric stiffening effect by increasing the area moment of inertia. This reduces carbon fiber (CF) material within CF-reinforced plastic (CFRP) components, and thus, the CO2 footprint. A suitable material combination for lightweight design is the use of continuous fiber-reinforced face sheets with a light foam core. CFRP sandwich structures with foam core are manufactured by combining a prefabricated foam core with fiber-reinforced cover layers in a two-step press process. Besides the reduction of the used CFRP material, more efficient manufacturing processes are needed. The aim of this paper is to develop a novel polyurethane foam system to enable the direct sandwich composite molding (D‑SCM) process for the production of CFRP sandwich structures by utilizing the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF reinforced face sheets. The developed formulation enables D-SCM structures with 150–250 kg/m3 foam density and 44–47.5% fiber volume content, based on a preliminary evaluation.

Epoxy resins are widely used in composite materials for aircraft applications.However, they are difficult to recycle, thus posing an increasing challenge to the aviation sector. By contrast, polyurethane resins (PUR) can be easily chemically recycled by solvolysis, but structural parts made of carbon fibre-reinforced polyurethanes (CF-PURs) are currently not in use in aircraft applications. This is due to a lack of knowledge about the properties of CF-PURs, especially during exposure to higher temperatures and to fire. To increase the recyclability of aircraft parts, for example interior structures like seats, there is a need for CF-PUR components which are able to fulfil the flame retardant regulations as well as the quality and production cycle time requirements of the aviation industry. It was found that a CF-PUR formulation processed by wet compression moulding containing 9 wt% of a phosphorous polyol is able to fulfil these requirements for aviation interior applications.

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Sandwich structures benefit from the geometrical stiffening effect due to their high cross-sectional area moment of inertia. Transferred to carbon fiber-reinforced plastic (CFRP) components, the needed amount of carbon fiber (CF) material can be reduced and with it the CO2 footprint. The combination of a light foam core with continuous fiber-reinforced face sheets is a suitable material combination for lightweight design. Traditionally, CFRP sandwich structures with a foam core are manufactured in a two-step process by combining a prefabricated foam core with fiber-reinforced face sheets. However, in addition to the reduction in the used CFRP material, manufacturing processes with a high efficiency are needed. The objective of this paper is the sandwich manufacturing and characterization by using the Direct Sandwich Composite Molding (D-SCM) process for the one-step production of CFRP sandwich structures. The D-SCM process utilizes the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF-reinforced face sheets. The results of this work show that the production of sandwich structures with the novel D-SCM process strategy is feasible in one single manufacturing step and achieves good impregnation qualities. The foam density and morphology significantly influence the core shear properties and thus the component behavior under a bending load.