Flexible Infrared Curing System

The growing use of composites in military aircraft and the corresponding rise in repair complexity, particularly in low-visibility fighter and bomber aircraft material, necessitates advances in curing technology, in particular, the development of a method that targets cure time reduction and thus allows aircraft maintenance crew to accelerate the repair cycle of aircraft outer mold line (OML). To address this Air Force need, Physical Optics Corporation (POC) proposes to develop a new Flexible Infrared Curing (FIRC) system. This proposed device is based on novel integration of an array of high-intensity infrared (IR) light-emitting diodes (LEDs) and POC’s patented light-shaping diffusers to provide high-power IR heating source for curing. These innovations enable the low observable coating being heated from the inside out without heating the air as in a conventional oven. Combined with its flexible structure, the FIRC system provides user the capability of fast and effective curing even on cured surfaces and accelerates the repair cycle for current stealth B-2 and F-22 materials. In Phase I, POC will demonstrate the feasibility of FIRC by developing a proof-of-concept prototype to demonstrate repair cycle time reduction. In Phase II, we plan to develop a fully functional prototype FIRC and conduct field tests. BENEFIT: Military applications of the FIRC system will include reduced repair cycle time for material stack-ups that decrease maintenance time and increase the pace of flying the aircraft as frequently as required. The FIRC system can be incorporated by the U.S. Air Force into the next generation fighter and bomber aircraft for in-field repair, which will benefit from FIRC technology. The proposed FIRC system can be incorporated by all commercial planes, automobiles, and boats to shorten cure time during manufacturing and repair.