Ballistic Missile System Composite Integrated Missile Harness Fairing Assembly

The proposed development effort will demonstrate a lower cost, more reliable manufacturing approach for providing electrical continuity between the missile electronics and the propulsion sections for the Kinetic Energy Interceptor (KEI) program. The Integrated Missile Harness Fairing Assembly (IMHFA) is a design and manufacturing concept where the electrical interconnect assembly and fairing are fabricated as an integrated unit. Flex cables in foam sandwich with integral connectors are co-cured in a composite laminate. The assembly is fabricated and quality tested off-line of the missile primary assembly line, affording a lower risk and more rapid modular assembly line approach. In addition to increased electrical reliability, the concept will reduce cost and on some missiles will improve aerodynamics due to the conforming shape of the IMHFA. This Phase I program will develop a design concept for the KEI using a design for manufacturing and assembly process, will select materials, will analytically verify the structural approach, and will fabricate a sub-scale demonstration article.