Highly Efficient Topology Optimized Composite Structures

Electric air vehicles, especially eVTOL aircraft (electric vertical takeoff and landing, eVTOL), have demanding requirements, much more so in some respects than conventional commercial aircraft. Key demands include: range, or the distance it can fly on one charge; ability to meet high production rates; a robust and reliable airframe, that is, the ability to withstand damage and be easily inspected and maintained; and an economical production cost. This STTR proposal addresses those demands though a novel approach to Advanced Aircraft Materials and Manufacturing. Getting the most range per charge is critical. A primary driver of range is vehicle weight. Vehicle weight is directly affected by the airframe design and materials chosen. Composite construction, typically carbon reinforced composites, are used for their light weight and high strength. Typical commercial aircraft, such as the Airbus A320 and Boeing 737, have production rates of about 40 – 50 per month. At full rate production eVTOL’s may reach rates of 200+ per month. The ability to manufacture higher rates is directly driven by the method of manufacture and the ability to include automated processes. That is, conventional methods of commercial aircraft manufacture will not enable high rate production of eVTOL. Traditionally, composite structures such as aircraft skins and wing panels, are reinforced using honeycomb or foam core bonded into the structure, a “core stiffened panel”. Core is lightweight, but has several disadvantages: core requires separate machining before use, which slows manufacturing time and adds cost; core can be expensive to purchase; core is adhesively bonded to the skin, adding manufacturing cost and time; the bonded core can fail due to fatigue; core can be damaged by exposure to moisture; damage to the core is not easily detected or repairable; and core cannot be easily optimized to efficiently distribute the structural loading. Building off the success of Phase I this project will leverage University of Dayton Research Institute (UDRI) expertise in topology optimization to design and fabricate a light weight and structurally equivalent/optimized wing; Spintech expertise in designing and fabricating complex composite structures using novel tooling solutions; and Aurora’s history and expertise in air vehicle design and manufacturing. The key team members have experience and expertise in the skills needed to successfully accomplish the work and past experience commercializing products and solutions.