Automated Fiber Placement (AFP) Process for Polymer Composite Sabots

Automated Cynamics Corporations (ADC) proposes to exploit its knowledge of automated in-situ consolidation of thermoplastic carbon fiber unidirectional tape to reduce the high scrap rate currently experienced in the in the fabrication of thermoset (epoxy) carbon fiber sabots. The current production process requires several steps which result in material loss (scrap) of approximately 60-70%. Approximately one half of the loss results in converting unidirectional tape to wedges in a multi-step, labor intensive process. An automated in-situ consolidation process using commercially available thermoplastic carbon fiber prepreg offers the potential to eliminate virtually all of the material waste in fabricating the wedges. Additional significant material savings may be available if a lower weight near net-shape, can be fabricated using the automated process. In addition, potential productivity enhancements due to automation and reduces labor requirements may be available. Finally, the use of thermoplastics versus thermosets brings several advantages: 1. Enhanced performance due to outstanding toughness. 2. Material scrap and rejects are recyclable. 3. Infinite shelf life versus limited thermostet life based on out-time. 5. Reduced VOC's 6. No special environment is required for in-situ fabrication.