This study provides a detailed consideration of five manufacturing <br/>options that are used to produce aerospace sandwich panels used in secondary <br/>structure. The structural performance of each of the manufacturing options is <br/>considered along with a cost analysis. By considering the traditional preimpregnated <br/>(prepreg), autoclave-cured process, the sources of cost have been investigated, and it <br/>has been shown that by removing a portion of the large labor content and the <br/>autoclave cure, in favor of an oven-only cure, it would be possible to make <br/>significant savings. Monitoring the time to manufacture representative full-scale <br/>sandwich panels using the five manufacturing options has shown that by using a <br/>resin film infusion (RFI) oven cure, a 30% reduction in time to production is possible. <br/>To make an initial assessment of the comparative structural performance of <br/>laminates produced using the five manufacturing options, this article also presents <br/>results of material quality, in-plane and out-of-plane loading tests. The results of <br/>these tests show that the laminates produced using RFI are comparable in quality <br/>and performance to laminates produced using the current aerospace industry <br/>standard prepreg/autoclave process. <br/
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