Low Cost, Light Weight Composite Structures Using the Quickstep Manufacturing Process Technology (PVCI-001)

Carbon fiber composite structures provide light weight and high performance solutions for military aircraft. Alternative Out-of-Autoclave (OOA) processes are needed to reduce manufacturing costs of composite structures and increase their usage for aerospace systems. Quickstep is a low cost alternative to autoclave processing, which uses large capacity fluid storage tanks and heat transfer fluids to directly heat the part and tooling and control temperature during processing, Quickstep can use either aerospace grade qualified prepreg materials or non-impregnated materials that are resin infused. The tool and part are encased to create a floating pressure equilibrium environment eliminating the need for tooling backing structures. A program is proposed to demonstrate low cost, lightweight composite structures using the Quickstep process as an alternative to autoclave processing for Navy system applications. In Phase I, sub-scale test articles will be fabricated using Quickstep and autoclave processes and tests conducted to demonstrate equivalent properties but lower cost of Quickstep. The Phase I option will study tooling materials and fabricate sub-element articles. In Phase II, Vector along with Boeing and the Navy will identify full-scale test articles to be fabricated and tested using the Quickstep process technology.