Experimental and simulation study of resin infiltration in carbon fiber rovings

Continuous-fiber-reinforced polymers are vital for lightweight structural applications, where fiber–matrix wetting critically influences composite performance. Understanding dynamic wetting behavior during resin infiltration remains challenging, especially under realistic processing conditions. Here we investigate the dynamic wetting of commercial carbon fiber rovings by a commonly used epoxy resin through combined optical experiments and two-phase flow simulations informed by mesoscale roving geometries. We measure velocity-dependent advancing contact angles and observe roving geometry changes during capillary-driven resin infiltration. Simulations using mesoscale-derived capillary pressure and permeability parameters quantitatively reproduce the time-dependent infiltration dynamics. Our findings demonstrate that while dynamic contact angles vary with velocity, the mesoscale roving structure predominantly governs resin impregnation behavior. This integrated experimental and modeling approach enhances insight into fiber-resin interactions, offering a pathway to optimize composite manufacturing processes and improve material quality.