Innovative Degassed, Densified, Pre-Charged Molding Compound for Rapid UAS Parts Manufacturing

Enabling affordable mass UAS parts for next generation systems increases the US readiness to efficiently respond the future threats. Common prepreg, sheet molding compounds, or bulk chopped prepreg products, can be expensive, require extensive touch-time for cutting and lay-up operations, and require high pressure compression methods to debulk and remove porosity. In this Phase II program, NanoSperse proposes to advance the development of a fundamentally new class of discontinuous fiber molding compounds by incorporating dry chopped fiber and resin into a fully degassed molding compound through a one step extrusion-type process.  Since the material is fully degassed and compacted, lower molding pressures and increased cycle times are achievable.  In Phase I, NanoSperse utilized its commercial aerospace qualified production line to produce 75 lbs. of a prototype, 50% fiber volume, degassed molding compound for trial by Cornerstone Research Group. In Phase II, NanoSperse will 1) improve mechanical properties of produced compounds through process modification to reduce shear 2) dramatically reduce compound cost through production rate improvements and raw material selection and 3) work with Cornerstone Research Group to validate UAS part production and advance the technology towards qualification. By utilizing US-sourced, aerospace qualified raw materials, manufactured in the US, a low-risk, high value product can be achieved and rapidly qualified, advancing affordable mass solutions for next generation UAS.