Compression Molding of Low-Cost Aircraft Structure

There is a national Defense-related mission need in the area of unmanned aircraft systems (UAS), specifically UAS manufacturing solutions for low cost, simplified composite primary structures. In a war of attrition, it is imperative to have a vehicle platform that can be rapidly manufactured and integrated at a very low cost while maintaining performance and operational utility of the system. CRG believes technology development under this effort could contribute to future mission need fulfillment. This objective suggests a solution that includes flexible design shapes with integrated structures as well as a rapid cure when compared to the historical autoclave composite solutions. Cornerstone Research Group Inc. (CRG) proposes to deliver greater affordability and reduced complexity, while maintaining structural integrity, for Air Force primary structure components by demonstrating compression molded technology that enables air vehicle cost reductions via reduced complexity. The technology can employ modeling analysis for compression molding components, making use of the building block methods as traditionally followed for autoclave prepreg designs in primary structures to support more rapid development cycles. This effort will accomplish the following: Demonstrate the structural viability of a compression molded composite structure for aerospace applications Demonstrate the ability to achieve rapid manufacturing times for composite structures  Demonstrate the cost reductions achievable from compression molding for aerospace structures