Manufacturing Technology for Affordable Composite Structures

Ebert Composites Corporation (Ebert) proposes to develop an advanced combined pultrusion and machining concept capable of producing affordable precision machined pultruded components for use in large composite structures. Previous research efforts have shown the merits of composite truss structures using a novel interlocking system developed by Ebert. The system allows assembly of structures without adhesives, bolts, or joint reinforcing material. Large, very high strength, easy to assemble structures are possible using relatively low cost materials. However, extensive precision machining of the base pultruded material is required to produce individual components of a structure. Previous research has also shown that this will require multiple machining steps separate from the pultrusion process to produce the strongest possible joint. These machining steps are time consuming, which restricts the ability to produce low cost components. During Phase I, Ebert proposes to design a pultrusion process that seamlessly integrates high speed precision machining. General machining concepts will be developed and tested using in-house equipment with a goal of demonstrating the capability of synchronized machining of pultruded components. The option period would develop a test truss structure and a pultrusion/machining specification as a lead-in to Phase II development.