Novel Prepreg based On-aircraft Repair (NoPORE)

A novel prepreg based on-aircraft repair technology is proposed. The C2Si team, with in-depth and hands-on complementary experience, will innovate on every aspect of advanced composite repair performed on-aircraft with limited equipment accessibility and short timeframe. Repair quality will be comparable and likely better than state-of-the-art (SOTA) materials and procedures. USC, as the subcontractor, brings in the unique prepreg format, superior cure chemistry resin and experience in out-of-autoclave, vacuum bag only low temperature SOTA process. Our team will bring in software implementable damage assessment and numerical analysis assisted damage area classification, repair area preparation, and laminated composite patch design process framework requiring workforce with only handheld equipment enabling reliable repair at the operation site. Our team will also demonstrate mechanical properties of the repair patch comparable or superior to AS4/EA 9390 resin wet layup double vacuum debulk processed panel. Successful completion of Phase I work will result in establishing feasibility of the NoPORE process and USCPreg based laminate meeting topic criteria at a proof-of-concept level. The end-to-end repair steps will be developed to follow in Phase II. Phase I will also demonstrate the relative advantages and process suitability of USCPreg based composite patch for on-aircraft repairs.