Materials and Manufacturing Processes for sensors, power, and communications of Unmanned Aerial Systems (UAS)

Continuous Fiber 3D (CF3D) manufacturing is a cutting-edge composite manufacturing technology that has the potential to enable higher-performing (e.g., specific stiffness, specific strength) and lower-cost (e.g., less material waste, minimized part count, reduced touch labor) structures for future Navy applications. CF3D works by combining dry fiber tows with liquid snap curing thermoset resin inside of a print head on the end of a six-axis robotic arm. As the composite is discharged and consolidated, it is snap-cured into place enabling the manufacturing of complex composite structures (e.g., fiber steering, stacking, tight contours) with high fiber volume fractions (>50%) and low void volume fractions (<2%). Advanced manufacturing techniques such as CF3D will benefit the Navy greatly as it continues innovative multifunctional materials for UAV structures. The proposed innovation is to combine structural elements with sensors, communications and other functional materials using the emerging CF3D® manufacturing process that are suitable for Navy UAV use. This proposal endeavors to advance and characterize the CF3D® materials and process through testing and model validation. Testing will be conducted at the coupon and representative structure sub-scale. The equipment manufactured and processes developed by Continuous Composite will enable many innovators and manufacturers to develop hardware for the Navy and customers with unique composite needs. Phase I Base will include FEA, coupon testing and functional evaluation of multifunctional materials along with the development and delivery samples that may be suitable for incorporating into UAV structures. Phase I Option with include further development, testing, FEA and test planning for Phase II.