An innovative approach has been developed to fabricate composite parts
with complicated geometry. The part is first divided into several sim
ple substructures and each substructure is produced by an optimal proc
ess. These preformed substructures are then assembled on a specially d
esigned tool and transferred into a mold cavity for resin impregnation
by structural reaction injection molding (SRIM). A composite link is
used as an example in this study. The mold filling pattern is simulate
d using a 3-D computer model. The simulated results compared well with
the experimental results when race tracking and fiber impingement eff
ects were considered in the model.