Precision Manufacturing of Co-Axially Hybridized Composite Rods and Other Precision Components for High Performance Space Structures

This proposal addresses composite fabrication technology aimed at production of very small, very detailed mono- and multi-material composite hardware for spacecraft applications. During Phase I, KaZaK Composites demonstrated tow important processtechnologies that improve the mechanical properties of structural elements used in deployable spacecraft booms. First, we designed and implemented a unique tooling system that eliminates the minimum size constraint of conventional fabrication technologyassociated with increasingly small structural component size. Second, we demonstrated a method that uses new tooling technology to produce very small, very detailed hybrid material structural elements that promise to significantly increase the performanceof composite elements used to make high performance carbon/phenolic precursor structure for carbon/carbon heat pipe tubing. KCI has secured commitments for two aerospace firms to supply matching funds to make comparative parts using more conventionalfabrication technology and KCI's new process, then to test the candidate parts made with new and old technology to verify the suitability of the new process for the fabrication of spaceflight-acceptable composites. KCI's new composite fabricationtechnology directly supports current aerospace coilable boom manufacturers by allowing them to meet projected needs for smaller masts that will be used in lighter, less expensive, future spacescraft systems. It is also an enabling technology for thefabrication of next-generation spacecraft thermal control systems. This same technology can be applied to the production of precursor for commercial composite components such as heat treating furnace structure. Very small composite rods may also findapplications in ver large deployable