Advanced Manufacturing Technologies (AMT): Composites Integrated Modeling

The Composites Integrated Modeling (CIM) Element developed low cost, lightweight, and efficient composite structures, materials and manufacturing technologies with direct application to the proposed Space Launch System (SLS) Exploration Upper Stage (EUS) mission.

CIM encompassed computational methods, tools and processes that go into the materials, design, manufacturing and qualification of composite aerospace structures. This effort proposed that test articles and analytical techniques be developed in order to investigate the appropriate treatment of model-based methods to achieve the maximum benefit of using the computational approaches for optimization of cost, performance, and reliability materials for launch vehicle structures such as the EUS. Materials Extend use of out-of-autoclave materials to load-bearing composite structures Introduce damage-based allowables to improve performance while reducing cost Reduce allowables variability Design Tailor composite wall construction to maximize load-carrying capability while minimizing mass Implement model-based integration of design and qualification/certification Reduce artificial knockdown factors by implementing damage-based allowables at a component level Manufacturing Implement model-based, automated manufacturing of relevant-scale structures Demonstrate light-weight bonded joint technology to reduce numbers of fasteners