Liquid Molded Composite Armor Smart Structures Using Embedded Sensors

Production Products will develop novel, low cost liquid molding processing technology and in-situ fiber optic sensors for in-service process, health and dynamic response monitoring of monocoque or hybrid composite armor structural parts. Both fiber optic sensors and ultrasonic spectroscopy will be used for cure monitoring, measuring dynamic response, strain, and structural health monitoring. In Phase I we will develop low cost techniques to place the fiber optic sensors in the liquid molded composite structures; fabricate representative Army composite armor components, perform cure monitoring using embedded fiber optic sensors; perform structural tests on components to demonstrate the ability of the fiber optic sensors to accurately measure strain, and track costs to show the impact on overall system cost of incorporating smart structures in armor components. Production Products will apply the sensor and liquid molding technology to Army applications and commercialize the technology in Phase II. The anticipated benefits of this program include: lowering the cost of fiber optic sensor technology by implementation into large volume Army armor applications, improved process control from cure monitoring sensors and accurate structural health monitoring during service. The technology has immediate military and commercial sales potential as well as broad applicability to a wide range of additional aerospace/commercial applications, including application to composite civil structures.