Manufacturing Assessment of Tailorable and Ultra-Thin TuFF Composites

NASA has shown interest in applying thin-ply, tailorable technology with the potential to reduce cost and weight (including minimum gauge designs) optimizing mass efficiency in aerospace and space components. Our approach will focus on small end fittings for struts but larger hollow structures such as the strut itself can be considered. Damage tolerance with thin-ply is key in propellant tanks, while minimum weight solutions with the potential for material reuse are critical for deep-space habitation structures.Key technical objectives of the proposed Phase II effort is: Develop TuFF stretch steering for AFP processes with 10x-20x smaller steering radius compared to continuous fiber tapes Demonstrate expansion and cure/consolidation of thin-ply, tailored TuFF preforms using bladder molding to produce high-performance hollow structures Design, fabricate and test high-performance end fittings reducing weight, allowing CTE matching to the composite structure and minimizing stiffness discontinuities seen in composite metal designs. The final deliverable will be the fabrication of composite end fittings for struts fabricated with the novel material and process solution. The results will demonstrate the potential to fabricate thin-ply, tailorable hollow structures for load-bearing applications reducing material weight with improved damage tolerance.         CA proposes to develop a materials and mfg. approach to produce ultra-thin ply and tailorable composite structures from short fiber, aligned TuFF material. This allows weight optimized designs (including variable stiffness designs) for space applications using stretchable, thin-ply composites made from short carbon fibers. Phase I has demonstrated our stretch steering approach using automated fiber placement (AFP) allowing 10x smaller steering radius (50mm) compared to continuous fiber tape (500mm) with a predicted 20x improvement possible. This allows high degree of design flexibility for AFP or other additive processes to create tailored, complex geometry parts.         Phase II combines stretch steering with thin-ply (60gsm and lower) TuFF to create conical, tailored preforms for bladder molding to produce high-performance hollow structures. CA will design and fabricate end fittings for structurally efficient tapered strut (SETS) integration. Scale-up from smaller to larger components such as the struts itself can be considered and will improve mass-efficiency for space structures.         The approach evaluates AFP placement of short fiber, thin-ply, steerable TuFF tape to create variable fiber orientation TuFF preforms and apply it to bladder molding of end fittings. Aligned TuFF material will be produced, and tape placed using the stretchable steering approach to fabricate tailored, thin-ply, high fiber volume fraction (~57% FVF) preforms for processing in the bladder molding approach. The preform will be expanded into the molds to create high-performance, hollow composites. Key is the ability of the TuFF material to stretch into the female mold surface. Finally, structural performance will be assessed. Key technical objectives are:   Develop TuFF stretch steering for AFP processes with 10x-20x smaller steering radius compared to continuous fiber tapes Demonstrate expansion and cure/consolidation of thin-ply, tailored TuFF preforms using bladder molding to produce high-performance hollow structures Design, fabricate and test high-performance end fittings reducing weight, allowing CTE matching to the composite structure and minimizing stiffness discontinuities seen in composite – metal designs           The results will demonstrate the potential to fabricate thin-ply, tailorable hollow structures for load-bearing applications reducing material weight with improved damage tolerance.    

NASA has shown interest in thin-ply, tailorable (steerable) technology to reduce cost and weight (including minimum gauge designs) optimizing mass efficiency. We will focus on small end fittings for struts in space frame applications but larger hollow structures can be considered. A NASA report on Passive Aeroelastic Tailoring has shown steering benefits in designs of wing structures while damage tolerance with thin-ply is key in propellant tanks. TuFF unique capability of material reuse/recycling can impact deep-space habitation structures. The general approach and specific technologies developed in this SBIR can also be applied to other commercial and military applications (aerospace, automotive, wind etc). These applications may require additional material testing and R&D to meet certifications and particular application requirements.

This is early/mid-stage (TRL 6) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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