Precision Heated Tooling for OOA Curing of Thin-Ply Composites

Touchstone designed and manufactured a lightweight self-heating composite tool that contains a graphite foam core and independent heater control for enhancing temperature uniformity and resin stability during cure. The technology is an alternative to conventional oven and autoclave curing of large composite structures. Moreover, the out of autoclave (OOA) and out of oven (OOO) composite tool technology should significantly reduce high operational costs and increase productivity in large structural composites manufacturing. The technology readiness level is currently at TRL-5 based upon a BMI-graphite foam core system with bottom mount heaters. It is proposed in Phase IIE to build and evaluate 3ft and 15ft prototypes per its aerospace partner specifications in support of Touchstones commercialization initiatives for heated tool technology, who has expressed a need for self-heated tooling to demonstrate high-rate fabrication of next generation commercial aircraft composite structures.

Composite materials offer significant advantages in space applications where weight reduction is paramount for deep space exploration. The intent of this technology development is to provide NASA with a more adaptable, or logistically favorable, process for curing large composite structures. The proposed technology offers benefits in deployable structures such as in reducing manufacturing costs associated with large capital expenditure in autoclave and oven technology and maximize operational facility workspace.

Touchstone foresees commercial opportunities for the BMI/GFOAM core composite tool in aerospace, space, marine, industrial and in the energy markets. A couple examples would be onsite production of large wind farm blades for energy production or composite deckhouse structures for Navy Ships.

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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