Rapid Low-Cost Manufacturing Techniques for Filament Wound Composite Structures

Filament wound composite structures are being increasingly used in tactical rocket motorcase applications to reduce weight and enhance system performance. Conventional fabrication methods for composite motorcase structures are time-consuming and often require expensive tooling. This Phase I Small Business Innovation Research (SBIR) proposal addresses the development and evaluation of rapid, low-cost manufacturing and processing techniques for filament wound composite motorcase structures. Specific areas to be investigated as part of the proposed Phase I feasibility demonstration include: (1) preimpregnated tow materials, (2) rapid electron beam curing processes, (3) low cost tooling designs and (4) back-to-back winding of full diameter opening motorcase structures. Each of these areas will be evaluated and compared through material/process trade studies and manufacturing feasibility investigations in order to select the most promising and technically feasible materials and process conditions for further development and demonstration as part of a follow-on Phase II program. Representative filament wound pressure vessels will be fabricated and hydrostatically pressure tested to compare the perforrnance of structures fabricated using the selected materials and processing techniques. BENEFITS: The primary application of the proposed research is filament wound rocket motorcases and launch tubes. Other applications for the proposed research include filament wound composite structures for the automotive, ship, aircraft, spacecraft and sporting goods industries.