Carbon Nanotube-Based Heater Coatings for Processing of Thermosetting and Thermoplastic Composites

For this research program, Mainstream will collaborate with Colorado State University (CSU) to develop a nanostructured heater capable of curing aerospace grade composites out-of-autoclave (OOA). The use of autoclaves is the primary cost driver in composite manufacturing due to size limitations, long processing times, and inefficient energy usage. Therefore, the Navy is looking to develop a nanostructured heater that can efficiently cure aerospace grade composites OOA without compromising quality. Mainstream and CSU are proposing a carbon nanotube-based heater that is capable of curing composites to autoclave quality while minimizing costs. The heater will be mechanically robust, reusable, and able to cure components with complex geometries and minimal energy usage. This heater will be used to cure composites OOA which will be compared to conventionally cured composites for degree of cure, mechanical strength and porosity. The processing of the proposed product is straightforward, allowing us to focus on scaling-up early in the project. For Phase II, we will develop aerospace grade composite components on the scale of 10 ft by 5 ft. The scaled-up heater will be used to cure composites that will be compared to conventionally cured composites for degree of cure, mechanical strength and porosity.