Reduced Cost Thermoplastic Composite Fabrication by Thermoforming Drapable Pre-pregs - P4954

Thermoformed thermoplastic composite parts can be produced in a common and relatively cost-effective way via thermoforming.Ý However, the process of avoiding wrinkles and maintaining tight tolerances can limit formability and therefore the geometric complexity of parts.Ý While a new generation of drapable ìdryî pre-pregs coupled with thermoforming processing techniques can reduce the number of steps and overall time for forming complex parts, these require a greater body of technical data and proven analysis tools tied to demonstration of representative parts in order to qualify and transition these materials for aerospace use.ÝMaterials Sciences LLC proposes to develop the technical data and an analysis toolset to facilitate fabrication of optimized complex thermoplastic composite parts. These will be guided by specialty coupon and component level studies to relate forming parameters to porosity, geometric tolerances, and mechanical properties, leading to production of a demonstration part. Such an approach requires improved methods for designing thermoplastic composites which optimize for both performance and cost, as well as an approach to expedite the qualification of such materials by using an enhanced understanding of thermoforming effects on material behavior to enable reduced effort and accelerate adoption of this technology in aerospace and other industries.