Low Cost, Low Weight Composite Structure using Out-Of-Autoclave (OOA) Technology

This SBIR Phase I proposal will demonstrate the manufacture of a OOA composite using infrared radiation and compaction technology, an innovative resin film, and a resin film infusion process to produce aerospace quality thermoplastic composite. A low concentration of IR absorber is blended into a resin polymer and cast as a thin film. The resin film is interleaved with a carbon fabric reinforcement and the sandwich is irradiated using focused infrared radiation while applying pressure from compaction rollers in a lamination process. The heat and pressure infuse the resin film into the fabric to produce a carbon-reinforced thermoplastic composite. The Phase I program will build the infrared irradiation and compaction roller processing unit, fabricate composite laminate and test to demonstrate aerospace grade performance vs. the autoclave benchmark. The Phase I Option will optimize processing conditions, fabricate and fully characterize the mechanical performance of the composite laminate. A software program will compute setpoints for tape placement processing of resin infusion prepreg for scaleup in Phase II. The laminate performance data and tape placement processing conditions will be used to select, design and manufacture an aircraft sub-component part in the Phase II.