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

xxxIn-situ fiber placement is able to offer a wide and robust processing approach that is well suited for many aerospace structures. Flat, single curvature and large radius complex curvature parts can be effectively handled with the current in-situ techniques. However, there are limitations associated with this process. The use of a rigid metallic consolidation applicator is routinely used in the in-situ process for a few different reasons such as extremely high processing temperatures and the need to evenly distribute the consolidation force across the width of the material. Depending upon material width, thickness, resin system and part curvature the use of a rigid roller to apply effective consolidation force is restricted. Additionally, with some in-situ processing approaches the ability to apply individual tows of material with a single processing head is problematic. Finding a modified or alternative approach to apply a consolidation force that is more conformable and demonstrate individual tow control is a way to make the in-situ process more valuable. Our objective in this Phase 1 SBIR will be to determine the feasibility of a conformable consolidation head, determine suitable evaluation criteria for structures made with a conformable head and design conceptual solutions for the issues at hand