Hybrid Thermoplastic Matrix Fabrication Methods for Missile Structures

To meet the objective of producing low-cost, high-performance composite structures that contain highly detailed features for missile and aviation applications, Materials Sciences Corporation (MSC) is developing technical data and analysis tools to implement hybrid composite material systems. In order to achieve this objective, MSC will leverage prior experience from Small Business Innovation Research programs that have focused on fabrication, analysis, and design of injection molding of fiber-filled material systems. This experience has enabled MSC to identify two material systems of interest that offer the potential to span the spectrum of performance requirements necessary to develop hybrid missile and aviation components. The first system is a thermoplastic hybrid system that maintains all of the benefits of fiber reinforced thermoplastic matrix composites, e.g., improved damage tolerance, virtually unlimited shelf life with minimal storage requirements, recycling options, etc. The second system consists of a tailored thermoset prepreg that is compatible with thermoplastic overmolding: the system overcomes limitations associated with thermoplastic prepregs, e.g., tape width, drapability, etc. Since the selected hybrid systems are viable commercial products, the program can focus on applied research rather than costly and basic research on material development.