What can occur from applying too many plies at once in a laminate?

When applying too many plies at once in a laminate, excessive exothermic heat can occur due to the curing process of the resin that binds the layers together. Each ply releases heat when it cures, and this heat builds up when multiple plies are laminated simultaneously. If the heat generated exceeds a certain threshold, it can lead to a condition called "exothermic runaway," where the temperature continues to rise uncontrollably. This can negatively impact the properties of the laminate, such as causing distortion, warping, or uneven curing, ultimately compromising the performance and integrity of the final product.

This understanding highlights the importance of adhering to manufacturer guidelines regarding ply application and curing processes to achieve optimal results in composite materials.