Multi-stage debulk and compaction of thick composite repair laminates

A method for fabricating a repair laminate for a composite part having an exposed surface, comprising:

• applying a release film to the exposed surface, the release film being in direct contact with the exposed surface;
• applying a first ply stack to the release film, the first ply stack having a first plurality of uncured plies, the first ply stack being in direct contact with the release film;
• compacting the first plurality of uncured plies;
• applying a second ply stack to the first ply stack, the second ply stack having a second plurality of uncured plies;
• compacting the second plurality of uncured plies;
• removing the release film from underneath the first ply stack and the second ply stack from the exposed surface;
• removing the first and second ply stacks from the composite part;
• applying bonding material to the exposed surface;
• forming an uncured ply stack assembly from the first ply stack and the second ply stack;
• bonding the uncured ply stack assembly to the exposed surface with the bonding material;
• and
• curing the ply stack assembly and the bonding material;
• wherein the first ply stack is compacted prior to the second ply stack being applied and subsequently compacted;
• wherein the first ply stack is located between the exposed surface and a heat source and the heat source is operated to apply heat to the first ply stack during compacting of the first ply stack;
• and
• wherein the temperature during compacting is below a curing temperature.