TECHNICAL POINT OF CONTACT (TPOC)
Aleene Falk
Michael Ballard
PROJECTED CMMC LEVEL REQUIREMENT
Level 2 (Self)
TECHNOLOGY AREAS
Air Platform
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Materials
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Nuclear
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Space Platforms
MODERNIZATION PRIORITIES
Advanced Infrastructure & Advanced Manufacturing
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Advanced Materials
KEYWORDS
composite; composite joints; carbon fiber preforms; tailorable pi-joints; scalable production; airframe structures; lightweight materials; structural performance; cost-effective composites; geometric flexibility; advanced materials
OBJECTIVE
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.
The objective of this SBIR topic is to investigate and develop cost-effective composite joint technologies capable of providing highly tailorable geometry and performance characteristics for a wide spectrum of aerospace applications. Current solutions for composite structural joints face significant limitations, including high production costs, constrained geometric adaptability, and challenges with scalability for surge manufacturing. This effort specifically aims to deliver innovations in carbon fiber preform architectures and manufacturing processes to address these challenges. The Phase I focus includes validating the feasibility of scalable manufacturing methods, designing and fabricating initial carbon fiber pi-joint test articles, and defining the design space for achieving optimized geometric flexibility and structural performance. The overall goal is to lay the foundation for scalable, lightweight, high-performance composite joint solutions aligned with the Department of the Air Force's needs for advanced air platforms and weapons systems while supporting modernization priorities in advanced materials and manufacturing technologies.
ITAR
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws.
DESCRIPTION
The Air Force seeks to enhance the performance, scalability, and cost-effectiveness of unitized composite structures by developing innovative manufacturing processes and carbon fiber architectures to advance composite joint technologies. Current solutions for composite pi-joints exhibit a tradeoff between geometric flexibility and mechanical performance. Existing back-to-back "L" joints provide customizable geometries but lower performance, while 3D woven pi-joints offer higher structural integrity but limited design flexibility. Both options impose significant cost and scalability constraints, which impede efforts to meet future Department of the Air Force (DAF) requirements for Autonomous Collaborative Platforms (ACP) and advanced weapons systems.This effort addresses these challenges by developing scalable and cost-effective composite joint technologies capable of tailoring geometry and achieving a wide range of performance envelopes. The focus will be on enabling the mass production of lightweight, durable, high-performance connections for composite airframes, facilitating the delivery of affordable, high-capability autonomous air vehicles, and advancing the DAF's tactical air dominance and long-range strike capabilities. Successful implementation will advance the DAF's capabilities to produce composite structures at scale while achieving desired mechanical and operational specifications.The solution will begin at a Technology Readiness Level (TRL) of 2, with fundamental research to explore design space and material configurations. By the conclusion of Phase II, the target TRL is 6, with validated prototypes demonstrated in a relevant operational environment. The primary Phase I objectives will include the identification of feasible manufacturing processes, preliminary design and testing of carbon fiber pi-joints, and a clear outline of geometric and performance constraints. Phase II efforts will expand to include refined fabrication methods, fabrication and testing of joint assemblies consisting of optimized carbon fiber preforms, and cost analysis to quantify the economic benefits of the new process at both low and high production rates.Phase I Activities:Perform a comprehensive literature review and trade study to benchmark current solutions for composite joints.Design and fabricate initial carbon fiber pi-joint test articles, demonstrating novel fiber architectures and/or manufacturing processes.Develop a preliminary process flow for converting dry fiber preforms into finished thermoplastic or thermoset composite pi-joints.Deliver a technical feasibility report including proposed geometries, material configurations, and cost projections.Phase II Activities:Optimize fiber architectures to expand design space and performance envelopes, meeting specific mission requirements.Develop and demonstrate scalable preform manufacturing processes, integrating advanced resin impregnation techniques.Fabricate additional pi-joint specimens tailored for diverse operational scenarios, including ACP airframe applications.Conduct standard joint mechanical testing to validate performance specifications.Provide cost models for low-rate initial production (LRIP) and high-rate surge production scenarios.Deliver detailed process documentation outlining geometric constraints, fabrication steps, and scalability considerations.Deliverables:Prototypes of carbon fiber pi-joints optimized for different geometries and performance targets.Tow path diagrams and material specifications for each delivered prototype.Mechanical test data, including failure envelopes under various loading conditions.Manufacturing process documentation, including a detailed breakdown of required equipment, materials, and processing steps.Cost analysis outlining the economics of low-rate and high-volume production pathways.By advancing from TRL 2 to TRL 6, this project will help the Air Force address critical needs for advanced composite airframes in future autonomous air systems and enhance the performance and affordability of U.S. defense platforms. Furthermore, the scalable and tailorable manufacturing processes developed under this effort will provide a significant leap forward in material innovation and design flexibility, directly supporting modernization priorities in advanced materials and manufacturing technologies.
PHASE I
The Phase I effort will assess the feasibility of scalable carbon fiber preforms with tailorable geometry and manufacturing parameters. Deliverables include a study on achievable preform geometries, manufacturing constraints, initial cost analysis, and design space definition targeting AF end-user needs, with a focus on enabling lightweight, durable, cost-effective solutions aligned with DAF operational requirements.
PHASE II
The Phase II effort will deliver validated carbon fiber pi-joint prototypes, demonstrating scalable, cost-effective manufacturing processes with tailored geometry and performance. Outcomes include mechanical testing under operational loads, preform optimization for aerospace applications, resin impregnation process development, and cost models for low- and high-rate production. Success criteria target TRL 6 prototypes with documented scalability and affordability metrics.
PHASE III DUAL USE APPLICATIONS
Phase III advances scalable, tailorable composite joints for cost-effective manufacturing of aerospace structures. Military applications include ACP airframes and advanced weapons systems. Commercial use spans automotive and aerospace industries. Entry TRL 6; efforts focus on preform optimization, process refinement, and DAF transition support, addressing surge production and lifecycle cost reduction.
REFERENCES
Ronald P. Schmidt, Shaw M. Lee, and Lee M. Cooke, Lockheed Martin Aeronautics Company, 3-D WOVEN PI PREFORM JOINTS: AN ENABLING TECHNOLOGY FOR LARGE COMPOSITE STRUCTURE , SAMPE Proceedings, Long Beach CA, May 18-22, 2008.Ronald P. Schmidt, Shaw M. Lee, and Lee M. Cooke, Lockheed Martin Aeronautics Company, Application of a Rapid Design Tool to a 3D Woven Structural Joint , AIAA SciTech Forum, San Diego CA, January 2-7, 2022.
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