Grid-Stiffened Launch Vehicle Fairing Development

"The Phase I program successfully demonstrated a novel technique for improving the cost effectiveness of grid-stiffened payload fairing structures fabrication. The feasibility of these methods was demonstrated through the manufacture of a test panel and theinitial development of the processing and tooling techniques. The Phase II program will further refine and develop these techniques resulting in improved affordability of grid-stiffened payload fairing structures. The approach is based on the patentedFoster-Miller Ultrasonic Tape Lamination (UTL) technology coupled with an innovative approach to grid node configuration and tooling resulting in a 50 percent reduction in collation time relative to the current state-of-the-art processing methods. The UTLtechnology is a key enabler to achieving successful out-of-autoclave processing of composite grid-stiffened structures. During the course of the Phase II program, we will develop critical structural and processing data needed for full-scale fairingdesign. The proposed program is well coordinated with other AFRL development initiatives, ensuring that the Phase II design and processing data meets the needs for future large composite payload fairing structures. The program culminates with fabricationof a grid-stiffened representative of the size and complexity of a realistic payload fairing structural shell (P-020070)."