SBIR/STTR
Laser Additive Manufacturing of Large Scale Polymer Matrix Composite Structures, Phase I
Project Introduction
A laser heating system (LHS) for the automated fiber placement (AFP) of thermoplastic composites (TPC) has recently been developed by Automated Dynamics to technology readiness level (TRL) three. This system represents the state of the art in out of autoclave, additive manufacturing of advanced polymer matrix composite (PMC) structures. It is particularly suited for manufacture of large scale structures as there is no oven or autoclave requirement while being compatible with a wide variety of thermoplastic polymers. Now that the prototype system has been developed, additional testing is required before it will be ready for production-level manufacturing. This proposal seeks to optimize and validate the Laser AFP process while advancing to TRL 4. This will be accomplished through coupon level mechanical testing to support predictable performance, development of additively manufactured tooling concepts to enable rapid development of structures with complex geometries, and a manufacturing demonstration of this effort embodied in a structure analogous to a pressure vessel.
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Anticipated Benefits
Potential NASA Commercial Applications: The potential for applications within NASA are endless. Obvious applications include pressure vessels (including large cryotanks), composite crew modules, rocket motor casings, shrouds, satellite components (including zero CTE laminates), flywheel energy storage, and many others. The ability to 3D print structures has caught the public's imagination and is currently in use on the international space station. The ability to 3D print advanced thermoplastic composite structures opens up entirely new applications and opportunities. Additionally, the technology can be extended to other material systems including metal matrix composites (MMC) and ceramic matrix composites (CMC). Additively manufactured tools can be automatically fiber placed with continuous fiber reinforced metals or ceramics. Automated Dynamics and Fabrisonics have collaborated on aluminum matrix composites AFP. This has applications for higher temperature applications and selective reinforcement aluminum structures. Similarly, extremely high temperatures can be achieved with AFP ceramic precursors on 3D printed tools. However, in this case, post processes are required to paralyze the ceramic precursor. Applications include rocket motor components, heat shields, and thermal protection systems for hypersonic vehicles.
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Primary U.S. Work Locations and Key Partners
| Organizations Performing Work | Role | Type | Location |
|---|---|---|---|
Langley Research Center
(LaRC)
|
Lead Organization | NASA Center | Hampton, VA |
| Automated Dynamics | Supporting Organization | Industry | Schenectady, NY |
Primary U.S. Work Locations
-
New York
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Organizational Responsibility
Responsible Mission Directorate:
- Space Technology Mission Directorate (STMD)
Lead Center / Facility:
- Langley Research Center (LaRC)
Responsible Program:
- SBIR/STTR
Project Management
Program Director:
Program Manager:
Principal Investigator:
- Zachary August
Project Duration
Start: Jun 2015
End: Dec 2015
Technology Maturity (TRL)
| Start: | 3 |
| Current: | 4 |
| Estimated End: | 4 |
Applied Research
Development
Demo & Test
Technology Areas
Primary:
- TA 12 Materials, Structures, Mechanical Systems and Manufacturing
- TA 12.4 Manufacturing
- TA 12.4.2 Intelligent Integrated Manufacturing and Cyber Physical Systems
Other / Cross-cutting:
- TA 12 Materials, Structures, Mechanical Systems and Manufacturing
- TA 12.1 Materials
- TA 12.1.1 Lightweight Structural Materials