Directed Heating System for High Speed Manufacturi

Polymer matrix thermoplastic (e.g., PEEK/IM7) composites exhibit excellent toughness, fatigue strength, and strength-to-weight characteristics over their all-metal counterparts. These characteristics make them desirable for high performance military structures such as artillery components for Mounted Combat Systems, aircraft components, and hulls for underwater vehicles. Currently, Automated Tape Laying (ATL) machines accomplish in-situ matrix heating, winding, and compaction of the composite prepreg tape onto mandrels. As a result of indirect and ineffective heating, both the prepreg winding tension and the tape feed rates are limited by the current ATL machines. Creare’s innovation is a novel Directed Heating System (DHS) that deposits directed and localized energy into the prepreg tape using a laser that can be easily and safely integrated with the fiber placement head on any ATL machine platform. During the Phase I project, we will assemble the DHS, complete pre-production tests on composite parts, and design the system for integration on off-the-shelf ATL machines. During Phase II, we will complete the system design, integration, testing, and transition the technology.