Innovative Low-cost, In-situ Consolidation Head for Complex Geometry Thermoplastic Fiber Placement

Accudyne proposes a SBIR program, endorsed by Sikorsky, Cytec Engineered Materials, and NASA-LaRC, to develop a cost-effective thermoplastic automated tow placement (ATP) process and demonstrate it by fabricating and testing a complex contoured skin (Phase 1) and a CH-53K rotorcraft lower cabin or ramp skin (Phase 2). The process employs in situ consolidation, avoiding the autoclave. The targeted part properties are those measured from autoclave-consolidated laminates. The selected Cytec APC-2 material system features inherent toughness, matching rotorcraft application requirements. For Phase 1, Accudyne will employ their already operating thermoplastic heated head that features full conformable compactors, individual tow-cut-and-add, and creates excellent microstructure. This plan will allow the rapid identification of the challenges to fabricating the complex contoured parts. Following Phase 2, Accudyne will offer an automated fiber placement machine and heated head for sale to the industry that is capable of fabricating the desired parts without using the autoclave.