Large, Low Cost Composite Pultruded Panels with Integrated Joint Edge Details Tailored for CHARC

KaZaK Composites and U-Maine propose to work with Lockheed Martin to develop and test state of the art composite materials, configurations and manufacturing methods meeting difficult structural, impact, weight and low cost objectives for application to Lockheed Martin’s CHARC LCS off-board vehicle. This proposal addresses technology development complementing and extending KaZaK’s current Ship-to-Shore and DD(X)-focused SBIR programs, specifically leveraging these current activities to maximize benefits for the CHARC design while minimizing CHARC development cost and risk. Material systems in our Phase I study will focus on impact-resistant off-board vehicle needs. Pultrusion processing will be emphasized for low cost composite manufacturing and its ability to cost-effectively integrate joining features into panel edge details for rapid assembly. During Phase I extensive material testing will be conducted by U-Maine to validate pultruded composite laminate design properties. In addition, pultruded composite panels will be joined for full scale joint testing. Laminate and joint test results will validate analytical and FEA models in support of future off-board vehicle design and material selection. If awarded a Phase II, our team will apply Phase I materials, configuration and manufacturing technology to the fabrication of hardware for a scale model prototype of the CHARC high speed vessel.BENEFITS: The proposed program will demonstrate the use of new materials and manufacturing systems as a viable alternative to traditional naval shipbuilding materials. In addition to obvious benefits to the military, these innovative lightweight and low cost composite material systems have the capability for rapid assembly, reducing acquisition cost. As the use of composites increases in construction, aero and marine industries processes that permit low cost manufacturing and significantly reduced composite structure assembly labor have the capability of meeting strict cost reduction requirements by the Navy. This ability to fabricate and assemble low cost composite structures has the potential to provide Navy and commercial ships better performance, less maintenance and significantly reduced lifecycle costs. Similar technology can be applied to a wide range of structures including piers, bridge decks, buildings, runways, and transportable shelters.