Highly Efficient Topology Optimized Composite Structures

This project will quantify the weight, cost, and manufacturing rate savings associated with redesigning existing core stiffened composite structures with non-cored, topology optimized, “organic iso-grid” reinforced skin structures. Manufacturing of the optimized designs will be enabled through use of novel material stitching techniques, tailored fiber placement (TFP), and Spintech’s’ patented Smart Tooling. The project team will also investigate the impact of material selection and method of manufacture on rate, quality and cost of the components, specifically resin infused dry fiber as it compares to pre-preg materials for these types of structures. The combination of TFP stitching, resin infusion, and Smart Tooling will allow for fabrication of composite structures that would previously have been deemed too complex or uneconomical to manufacture. The work product output of the Phase I program will be analytical results of a topology optimized structure as compared to a cored laminate baseline as well as a physical article demonstration that incorporates the organic topology optimized load paths co-cured with laminate skins.