Multi-stage consolidation process for ceramic matrix composite prepreg material

A method comprising:

• arranging a layup of a predetermined number of impregnated ceramic plies on a layup tool, performing a preliminary consolidation stage comprising:
• assembling a set of preliminary consolidation consumables over the layup, applying a vacuum pressure to withdraw air between the set of preliminary consolidation consumables and the layup, and heating the layup to a first predetermined temperature for a predetermined preliminary consolidation period to partially cure the layup, performing a final consolidation stage comprising:
• assembling a set of final consolidation consumables over the layup once the set of preliminary consolidation consumables are removed from the layup, the set of final consolidation consumables having a lower flexibility and a higher temperature capability than the set of preliminary consolidation consumables, applying a vacuum pressure to withdraw air between the set of final consolidation consumables and the layup, and heating the layup to a second predetermined temperature greater than the first predetermined temperature for a predetermined final consolidation period to fully cure the layup, wherein the set of preliminary consolidation consumables includes a perforated release film layer, a plurality of thin breather layers, a thick breather layer, and a vacuum stretch bag and wherein assembling the set of preliminary consolidation consumables over the layup comprises overlaying the perforated release film layer directly over an exposed surface of the layup, overlaying the plurality of thin breather layers directly over the perforated release film layer, overlaying the thick breather layer directly over the thin breather layers, and overlaying the vacuum stretch bag directly over the thick breather layer, and wherein the set of final consolidation consumables includes a perforated release film layer, a release film layer, first and second thick breather layers, and a high-temperature stretch bag and wherein assembling the set of final consolidation consumables over the layup comprises overlaying the perforated release film layer directly over an exposed surface of the layup, overlaying the first thick breather layer directly over the perforated release film layer, overlaying the release film layer directly over the first thick breather layer, overlaying the second thick breather layer directly over the release film layer, and overlaying the high-temperature stretch bag directly over the second thick breather layer.