Manufacturing Process Development of High-Performance Treated Honeycomb Core for Radar Absorbing Application

Current methods for manufacturing treated honeycomb core involve flow coat and dip processing of honeycomb core blocks. These processes yield low-performance parts due to limited capability to control process parameters and tolerances. Moreover, these processes limit the opportunity to incorporate edges with desirable radar-absorbing characteristics. Mikro Systems, Inc. (MSI) proposes to adapt its patented Tomo Lithographic Molding (TLM™) process to the manufacture of super-lightweight, intrinsically radar-absorbing, isogrid cores that will enhance system survivability, flexibility, and affordability. TLM™ is derived from established, photo-lithographic technology; it is very accurate and highly repeatable (low variation). Each cell of an isogrid core sheet can be a unique architecture combining polymer matrix composite materials and secondary geometric features; e.g., chines and corrugations. Collectively, these cells can be arrayed in a global architecture that optimizes strength-to-weight ratio while creating a multi-frequency (including sub millimeter), electromagnetic camouflage scheme. This Phase I SBIR project will design, fabricate, and test materials systems, hardware elements, and a Technology Demonstration Article ( 2’ x 4’ x ½” sandwich panel ) that will evidence Mikro Systems’ capability to scale-up and control all desired performance attributes. MSI cores composed of conventional (“non-stealthy”) materials and simple isogrid geometry have “dual-use” application in commercial products.