Optimized Novel Multifunctional Composite Sandwich Structures

Conventional sandwich composite structures, while offering high strength-to-weight ratios, suffer from critical limitations such as core-facesheet interface debonding, restricted design space for complex geometries and multiaxial loads, and challenges in integrating multifunctionality without performance penalties. These issues limit their optimal use in demanding naval aircraft applications. The need for advanced designs with improved bond strength, tailored performance, and inherent multifunctionality is critical. To address this, NextGen Aeronautics, in collaboration with ARCTOS Technology Solutions, proposes to develop advanced sandwich composite structures utilizing additively manufactured cellular cores. Our approach leverages Laser Powder Bed Fusion to create optimized core topologies with integrally designed features for enhanced core-facesheet bonding and embedded thermal/mechanical multifunctionality. The proposed Phase I effort integrates advanced computational modeling and experimental validation through mechanical and thermal testing of fabricated coupons. A series of tests will be performed during the Phase I effort to evaluate the performance of these novel structures, focusing on bond strength, mechanical properties compared to conventional core materials and geometries, and the demonstration of thermomechanical multifunctional capability. We anticipate achieving a Technology Readiness Level (TRL) of 3 during this Phase I effort, establishing the feasibility and providing robust prototype development plans for a potential TRL 6 system in Phase II.