Evaluation of Topological Composites for Weight Reduction in VTOL Aircraft

A novel microstructural phenomenon in 3D printed polymer composites has been discovered, which yield unusually high strength and stiffness. This results in excellent properties not only in the primary print direction, but also transversely to the printed beads. This project will further quantify the properties of this process and evaluate the out-of-plane transverse properties. Based on the property data that exists now, it is possible to replace machined aluminum parts with a lighter alternative, especially in stiffness-driven applications. While the properties achievable are lower than the state-of-the-art in high performance aerospace parts (Mantis Composites), they are high enough to provide an intermediate advantage over alloys.  Additionally, the inherent multi-directional properties from 3-axis printing that will be validated will allow the process to provide an advantage as a drop-in replacement at a low cost, whereas traditional 3D printing often requires extensive re-design. This STTR will generate b-basis allowables, FEA simulation to quantify the weight-savings potential for VTOL applications, and establish the scope (size, complexity) of manufacturable parts. [Note, we did not intentionally bold this content. It was a bug in the website or in Chrome that prevented un-bolding.]