Novel Rotomolding of Advanced Composites for Rocket Motor Cases

The future of enhanced tactical missile systems hinges on the development of significant innovative improvements in the manufacture of solid rocket motor casings. Leading engineers in the solid rocket motor industry believe further development with metalcases will not prove adequate. Current manufacturing of composite motors is labor intensive and the end product is simply inadequate overall.The consensus is that the future needs may be satisfied by the use of continuous fiber reinforced three-dimensional (3-D) microstructural composites made with advanced resin systems and materials. In order to mass-produce a more ideal rocket motor a newprocess must be developed that will turn out highly structured composite parts consistently and in a manner that minimizes skilled labor input.We propose to incorporate the use of advanced materials into our existing composite rotomold tank process and further the development of the rotomold process to manufacture multi-layer composite microstructured solid rocket motor cases to be used forfuture tactical missile development. The extension of this technology to the manufacturing of solid rocket motors will bring significant unit cost reductions.This proposal discusses Rotomold composite development and advanced composite materials processing for the low-cost manufacturing of composite solid rocket motors. The development of this technology will provide the means for actualizing current enhancedtactical missile system concepts. One of the primary limiting factors of these enhanced systems has been propulsion. By overcoming this limitation a new aerospace market of advanced missile system development and high performance propulsion will beestablished.