Compression Molding Fabrication of C/C Composite Produced via Highly Processable BODA-Derived Precursor Resin System

Bis-ortho-diynylarene (BODA) resins are an emerging class of high-char-yield (>80%) carbon matrix precursor resins that offer enhanced processability compared to industry-standard phenolics. In this study, a carbon-carbon composite was fabricated using a BODA-derived resin system (BDR) through a one-step powder-melt infusion and compression molding process. A novel high-temperature, 10-ton heated press process was developed to successfully cure BODA-derived resins, enabling the production of carbon-carbon composite coupons within two days while maintaining an 80% carbon yield. This paper examines the manufacturing challenges encountered during processing and the resulting optimizations that improved composite quality and consistency. This work demonstrates a streamlined processing route for BODA-based carbon-carbon composites, contributing to the advancement of high-char-yield precursor resin systems for aerospace and high-temperature structural applications.