A Low Cost Production Process for Large High Temperature Polymer Matrix Composites
DOD-Air Force Phase I STTR Contract FA9550-07-C-0071
Eltron is conducting research into the development of a cost-effective and reliable production method for fabricating large carbon fiber reinforced polyimide composites. Eltron and the Southwest Research Institute (SwRI) are working together to achieve this objective. Eltron has already developed a vacuum-assisted resin transfer molding (VARTM) process for producing high-temperature polyimide composites. SwRI has already developed process technologies and control algorithms for intelligent materials processing (IMP), which combine real-time sensor information, kinetic, and transport models with an artificial intelligence (AI) control system to optimize the cure conditions of composite processing (otherwise known as adaptive cure processing). This partnership will combine complementary technologies, with the goal of developing a low-cost process for producing large, aerospace composite parts. Part quality will be determined by measuring key performance metrics including mechanical, rheological, thermal, kinetic, quality, and environmental endurance properties. During composite part production, all experimental variables will be measured by Eltron and then provided to SWRI in support of their process modeling program.
This DoD-sponsored STTR research effort will result in a technology that provides a critical capability to the U.S. Air Force, where a reduced-cost approach to large high performance composite production will improve mission effectiveness. Cost savings in capital equipment, (out-of-autoclave process) reduced part and fastener counts, and in fabrication labor will be realized. By collaborating with a major research institute and a military aircraft manufacturer, the inherently high-risk associated with transitioning this technology to the warfighter will be minimized.
Potential commercial markets for this production process are very significant. The technology could be applied to the fabrication of large, high-temperature resistant composite structures for use in aerospace, automobile, watercraft, or other industries where weight, high performance and cost of ownership are prime concerns. Upon proof of concept and in conjunction with our commercial partners, we anticipate that a production process will be ready for transition to the US Air Force at the end of Phase II or early in Phase III research.