Automated Thermoplastic Tape Preform Lay-up for Secondary Closed Mold Consolidation for High-Rate Production of Complex Geometries

This proposal will demonstrate thermoplastic preform fabrication using existing proven processes in a novel, high value method, combining automated tape lay-up (ATL) and Smart Tools to enable efficient production of complex and convex geometries, with secondary mold consolidation to increase production speed and throughput. Current thermoplastic processes, due to the size of the equipment, are limited to creating preforms with simple geometries where the ATL can fit into the concave tool. Since concave tools are used to make convex parts, there are a significant number of convex parts where ATL production is desired but cannot be used, like tight radius wing leading edges, propellers, and aerodynamic fairings. Smart Tools allow efficient production of complex parts since they are rigid for lay-up and then become elastic for demolding, and then are reformed for reuse. Using a convex perform Smart Tool allows ATL preform fabrication, which can then be easily demolded and placed in a concave mold for consolidation. This project will develop and validate a scalable method to produce complex preforms using ATL on Smart Tools, enabling a full-scale article to be produced in Phase 2. This technology has wide application in the commercial and defense market, such as on UAM’s.