We are infusing a small flat sheet as shown in the picture but we keep running into a problem with the infusion using a lot more resin than expected.

We are using 2 layers of 200gsm CF with 10mm easycell infusion grooved foam in between. We estimate that for 1 sqm of the laminate, we will need 400 grams of resin (for the 2 layers of 200gsm CF) plus another 700 grams for the infusion mesh, with an extra 100 gm for the lines.

The infusion starts nicely and at a decent speed, but the problem is that the resin runs out with 50% only of the part infused or even less. We eventually had to put 3 times more than amount we calculated until the resin finally reached the vacuum port. This resulted in the part weighing twice as much as expected which is unacceptable as this is a very weight critical application.

What are we missing here ? this also happened with another part that was around 4 times bigger and we had the same issue. We did vacuum tests and by the time we opened the part the bag was very tight so we don't think it was a leak issue. We are using peel ply between the bag and the laminate at each side and a layer of infusion mesh on the top part of the laminate.

Yes Soric is also heavy. About 550g per m² per mm thickness. So yeh, a 2mm thick core will consume about 1100g of resin per m². 

I purchase pre-preg internationally from Easy composites, I believe they can supply most of the world without issue. Their XC110 has an out-life of 1 month (actually lasts longer in my experience) and they deliver to me in Australia within 3 days, so that's no issue.

Another option is to do it in a 2 or 3 shot process. Do you have to infuse it all in one go?