Development of a Simple Molding Method for Continuous Fiber Reinforcement FRP in Shapes with Highly Curved Corners

Portable devices are among the products made from fiber-reinforced plastic (FRP), which is characterized by high strength and low weight. The molding method for small devices involves use of flat sheets, but use of such methods for structures with highly curved corners, for example portable devices with right angles, either results in wrinkles or requires that the FRP be cut into pieces, introducing discontinuities where failure is more likely to occur. This issue results when structures with highly curved corners are made using flat fabric, and it can be solved by creating a threedimensional fabric. This study proposes a new method for manufacturing three-dimensional fabric to cover highly curved corners and edges. The authors also carried out a four-point bending test of the edge portion of such fabric based on the method described in ASTM D 6435. The result is a new molding method for three-dimensional fabric FRP that promises to play a more useful role than conventional molding processes in manufacturing future portable devices.