Honeycomb core sandwich structures can be fabricated in the co-cure process bybonding partially cured thermoset prepreg sheets with an adhesive layer to either side of the honeycomb core structure under a selected pressure and temperature cycle in theautoclave. The co-cure of honeycomb core sandwich structures is strongly dependent on many materials and process parameters such as prepreg facesheet consolidation, adhesive bond-line fillet formation, porosity development within facesheets and theadhesive, and the dynamic core pressure. This paper describes the fundamental physicsassociated with the co-cure process of sandwich structures and present numericalmodels describing the facesheet consolidation, adhesive bond-line fillet formation, and bond-line porosity during the co-cure process.
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