Low Cost, Low Weight Composite Structure using Out-Of-Autoclave (OOA) Technology Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-030 Topic Title: Low Cost, Low Weight Composite Structure using Out-Of-Autoclave (OOA) Technology Proposal No.: N081-030-0057 Firm: Kubota Research Associates 100 Hobson Drive Hockessin, Delaware 19707-2106 Contact: Masanori Kubota Phone: (302) 683-0199 Web Site: www.kubotaresearch.com Abstract: This SBIR Phase I proposal will demonstrate the manufacture of a OOA composite using infrared radiation and compaction technology, an innovative resin film, and a resin film infusion process to produce aerospace quality thermoplastic composite. A low concentration of IR absorber is blended into a resin polymer and cast as a thin film. The resin film is interleaved with a carbon fabric reinforcement and the sandwich is irradiated using focused infrared radiation while applying pressure from compaction rollers in a lamination process. The heat and pressure infuse the resin film into the fabric to produce a carbon-reinforced thermoplastic composite. The Phase I program will build the infrared irradiation and compaction roller processing unit, fabricate composite laminate and test to demonstrate aerospace grade performance vs. the autoclave benchmark. The Phase I Option will optimize processing conditions, fabricate and fully characterize the mechanical performance of the composite laminate. A software program will compute setpoints for tape placement processing of resin infusion prepreg for scaleup in Phase II. The laminate performance data and tape placement processing conditions will be used to select, design and manufacture an aircraft sub-component part in the Phase II. Benefits: This resin infusion material and composite manufacturing process has a wide-ranging applicability in the transportation segment for both military and commercial use. Military and commercial aircraft design has moved to extensive use of composite materials for weight reduction at equivalent or greater strength and toughness. Likewise, the commercial business jet market continues to expand the use of composites in manufacturing. In addition, automobile manufacturers are incorporating composites in structural applications in future models to address fuel economy while maintaining safety. Therefore, this OOA technology addresses the need for increased manufacturing productivity and lower cost in the transportation manufacturing segment and can expect to rapidly penetrate the composite airframe market using US-developed technology. This project also benefits an undergraduate engineer who will participate in research and training on this program. Return