Cost Effective Materials and Manufacturing for Range Extension Wing Kits

"Triton Systems, Inc. proposes to design, fabricate, test, and demonstrate low cost through technical cost modeling, the feasibility of an Advanced Thermoforming Technology AT2 manufacturing method for the production of range extension wing kits. The AT2approach is expected to provide a factor of two reduction in cost for these wing kits through the application of low cost tooling, high performance/cost ratio materials and the sophisticated application of cost modeling tools. Triton Systems has teamedwith Leigh Aerosystems, a leading supplier of range extension wing kits, and Ibis Associates, the leading cost analysts for composite production. The proposed Phase I program will trade-study the candidate composite materials and processes, demonstratethe fabrication of a Leigh Aerosystems "Longshot" composite wing, and validate the structural performance of the prototype wing.The U.S. Air Force needs to develop lower cost materials and manufacturing methods for winged autonomous munitions to allow broader fielding of the range extension kits, and to improve maneuverability, impact accuracy, standoff distance and pilot safety.To reach cost ratios that support extensive fielding, the program goal is for production costs to be reduced by as much as a factor of two. The successful completion of the Phase I program will result in the identification of the optimum manufacturing approach (materials, molding processes and assembly) for the pr