Maintainable, Survivable, Low Cost Composite Engine Inlet Filter and Housing Navy SBIR FY2005.2 Sol No.: Navy SBIR FY2005.2 Topic No.: N05-101 Topic Title: Maintainable, Survivable, Low Cost Composite Engine Inlet Filter and Housing Proposal No.: N052-101-0580 Firm: KaZaK Composites Incorporated 10F GIll Street Woburn, Massachusetts 01801-1721 Contact: Nate Gravelle Phone: (781) 932-5667 Web Site: kazakcomposites.com Abstract: KaZaK Composites will work with Pall Aeropower, a worldwide leader in aircraft filters, to develop and demonstrate next generation helicopter filtration systems that incorporate a new lightweight, low cost, damage-resistant structure in combination with advanced approaches to particulate removal. This team will apply leading edge technology to solve the specific filtration problems outlined in the SBIR solicitation. Phase I will initiate with a careful compilation and evaluation of the military's objectives and requirements for the new filtration system. We will then develop several design approaches that combine different material, configuration and manufacturing technology alternatives, and trade these alternatives against requirements to select an optimal approach. Analytically determined weight and performance predictions will be verified in both the basic and option portions of Phase I. A considerable amount of hardware fabrication and testing will be conducted at in-house facilities of KaZaK and Pall. Phase I will conclude with verified prototype hardware that should provide the government with sufficient confidence in the design to move forward into Phase II. In Phase II the KaZaK team will finalize system designs based on Phase I experience and military comment, and then proceed to fabricate and test full scale hardware. Benefits: Two primary technologies will be developed and demonstrated in this SBIR. First, advanced filter systems will be conceived and demonstrated, leading to more cost and weight effective methods for removing particulate matter from inlet airflow. Second, new cost effective composite hardware solutions will be developed to replace baseline aluminum hardware, reducing overall system weight and with it increase the performance of weight-critical helicopter systems. Because weight is so important to military helicopter performance, this type of vehicle will be the first adapter of the newly developed technology. Once proven for military helicopters, similar designs can be sold to commercial helicopter operators located in dusty areas of the world, or operating in dust-intensive operations. Military vehicles, because they spend 100% of there operating time on the ground, face even more critical and difficult issues with dust removal. While weight of the filter system has traditionally not been a major concern for designers of tanks and other large military systems, new emphasis on high mobility is expected to lead these systems toward any weight-saving improvements that are economically viable. We believe that the lightweight housing and improved air filtration methods to be demonstrated by this proposed SBIR will help position KaZaK and our teammate Pall Aeropower for greatly expanding sale of this type of hardware to land vehicle systems. Return