Innovative high-speed production process for 3D composite tooling for non-critical composite parts and repair.

This Phase I SBIR contract proposes finding a U.S. Air Force end user interested in adapting Gencores novel robotics and additive manufacturing platform to produce foam master molds for composite tooling. In this phase, a prime contractor such as Lockheed Martin – see letter of support – and the Air Force Material Command will provide guidance and end-user needs. Gencores technology will enable cutting 80% of lead times and 50% of costs for high-temperature composite tooling while avoiding both regulatory and new material specification complications. The associated Phase II schedule will validate the effort's strategy by producing a small number of composite tooling parts. The subsequent Phase III effort will focus on transitioning, refining, and deploying the developed technology. The step improvement in manufacturability of leading-edge composite technologies we propose will considerably strengthen the strategic and operational readiness of the U.S. Air Force.