For resin matrix composites, voids are common defects that can seriously deteriorate the properties of the composite parts. Thus, the elimination of voids is a crucial element in controlling the manufacturing process of composite parts. This article focuses on void formation originating from hygroscopic water for resin matrix composite laminates prepared with hot pressing process. The Kardos void formation model was developed to analyze the critical resin pressure for the initiation of voids, and the influencing factors were investigated experimentally to validate the modified model. It is found that resin pressure and gel temperature are the two key parameters to control void defects and that entrapped air in prepreg stacks must be considered in the void formation model. Furthermore, a simple method was established to measure the relationship between porosity and the processing parameters, and the void formation conditions of the resin and the prepreg stack were also studied. The theoretically predicted void formation conditions and the experimental results were compatible for the studied cases. These results are valuable for eliminating void defects, optimizing processing parameters, and enhancing the performance of composite parts.
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