Next Generation Carbon Fiber Composites for Aircraft

Atomic-6 is a United States-based advanced manufacturing firm specializing in environmentally friendly, next generation composite parts. Through a proprietary process, currently filed as a provisional patent, that includes both novel tooling design and a novel resin infusion process, Atomic-6 provides benefits such as: 1) exponentially reduced manufacturing costs; 2) the highest performing composites available in the market; and 3) up to a 98% reduction in autoclave cycle times compared to existing manufacturing processes. Atomic-6’s carbon fiber composite flat panel has been evaluated by Lockheed Martin Skunk Works (where the F-35, among other advanced aircraft, was developed) and has shown extremely favorable results. Using microscopy, Skunk Works visually confirmed Atomic-6’s carbon fiber composite panel was almost non-existent of void (air) content. Voids weaken the structural integrity of composite materials. Atomic-6 can produce parts that have less than 0.5% void content versus 1-5% commonly found in existing aerospace grade carbon fiber composites. In another test, Skunk Works confirmed the fiber to resin ratio of the material to be 63% fiber and 37% resin by volume, much higher than the next highest existing grades of carbon fiber composites on the market at 55% fiber volume – higher fiber volumes are indicative of better mechanical performance and lighter weight (resin dependent). This 8% increase in fiber volume equates to Atomic-6’s carbon fiber composite having a tensile strength that is 6,321 Ksi higher (14.22% improvement) than the next highest comparable grades of carbon fiber composites. The tensile modulus (stiffness of a solid material) was measured at 98% of the theoretical limit versus the historical 80% for carbon fiber composites. Lastly, Atomic-6’s process has eliminated the need for expensive pre-impregnated carbon fibers and reduced autoclave cycle times from 30 hours down to 20 minutes (resin dependent). This allows for an extremely cost-competitive product – at a potential price that is 80% less than certain high end aerospace-grade carbon fiber composites –  while still producing carbon fiber composites that are step change improvements above what is currently available.   Atomic-6 is teaming with Dr. Ramy Harik. Dr. Ramy Harik, a Fulbright Scholar, is a tenured Associate Professor in the Department of Mechanical Engineering at the University of South Carolina and a resident researcher at the McNAIR Center for Aerospace Innovation and Research. He was granted more than 3 million USD in funding from NASA, Boeing, Toray, SC Department of Commerce, South Carolina Research Authority, Siemens, Fokker Aerostructures, Dassault Aviation (funded as a student) and several other agencies. His research interests include carbon fiber composites manufacturing, process planning, CAD/CAM, automation, and advanced manufacturing techniques.