Innovative High-Temperature Phase-Change Tooling for Complex AFP/ATP Composite Structures

To address the shortcomings of current solutions and to meet the US Navy needs, Fiber Dynamics, Inc. (FDI) proposes to develop a new High Temperature Lost Core Tooling System (HT-LCTS). It is based on FDI’s commercial products and will employ our understanding of the unique requirements of producing removable tooling mandrels for complex, hollow aerostructures. The solution for In Situ Consolidated Thermoplastic Composites (ICS-TPC) will require a novel solution that has a surface layer that withstands the ISC-TPC thermoplastic processing surface temperatures, and conventional thermoset 350°F autoclave processing at 100 PSI. Furthermore, a solution comprised of a dissolvable outer surface capable of withstanding ISC-TPC processing via Automated Fiber Placement / Automated Tape Placement (AFP/ATP), supported by a meltable HT-LCTS would provide the optimal solution for both conditions. The proposed HT-LCTS not only addresses the major US Navy requirements for affordable, complex composite structures, but also has significant commercial applications such as the rapid production of tooling mandrels for commercial aerospace, sporting goods and automotive composite structures. In Phase I, FDI will demonstrate that the HC-LTCS concept(s) is capable of scaling to the fabrication of larger, complex, hollow thermoplastic and thermoset composite geometries. In Phase II, the tooling mandrel solution will reach technology readiness level (TRL) 7 to 8 and be ready for initial testing for potential transition to the Navy program determined by topic sponsor.