Durable, Low Cost Soil Stabilization Mat Optimized for Automated Pultrusion Manufacturing

XCraft Incorporated along with its team partner KaZaK Composites, Inc propose to develop and produce an innovative, low cost and pultrusion-based matting for soil stabilization applications. Developmental impetus for novel mat structures is based on an improved mobility need for heavily armored vehicles over soft soil expeditionary terrain. In Phase 1, XCraft down-selected WAVTRAC [wayv-trak] from several proposed candidates and demonstrated equivalent wheel loading capability / rut depth with up to 30% easier roll-up effort compared to the MOMAT baseline. Rigorous sub-element testing along with analytical and numerical models were used to demonstrate WAVTRAC capabilities for temperatures between -25F and 125F with good success. WAVTRAC, a semi-rigid 3-D undulated composite, is a similar but geometrically unique improvement of MOMAT, with easier roll-up, reduced handling abrasion, better UV durability, and lower cost. With a near-complete matting design from Phase 1, Phase 2 will emphasize rigorous sample testing for various sizes, sub-scale pultrusion manufacturing, and full scale pultrusion manufacturing. Pultrusion is the lowest cost composite manufacturing process with high throughput (feet/minute), capable of $7/ft^2 -$15/ft^2 matting Phase 3 cost. Four, 14ft x 60ft WAVTRAC demonstrative articles will be manufactured by the end of Phase 2 and delivered to MCSC for field testing.