Large Scale Thermoplastic Processing

TECHNOLOGY AREAS: Materials; Air Platform OBJECTIVE: This topic seeks to demonstrate the capability to process thermoplastic components on large acreage aerospace structures. DESCRIPTION: Thermoplastic composite materials can be consolidated into complex aerospace relevant shapes very quickly using press form or stamp forming processes. Many thermoplastic parts are flown on military and commercial aircraft today, however, these parts are typically small clips and brackets. This project will quickly identify, mature, and demonstrate a method to rapidly consolidate large aerospace components without the use of high temperature autoclave equipment. The contractor shall demonstrate the application of the technology on thermoplastic types PEEK, PEKK, or LM-PAEK or other government approved high temperature, high performance thermoplastic material for a large relevant aerospace part. The contractor shall validate that the consolidation process has resulted in a low void, high fiber volume part and will document cost, cycle time and weight savings compared to a traditional hand laid composite part processed in an autoclave. The proposed thermal solution should accommodate multiple part geometries and not be a stand-alone self heated tool that can only be used for a single geometry. PHASE I: As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made as a result of this topic. To qualify for this D2P2 topic, the Government expects the applicant(s) to demonstrate feasibility by means of a prior Phase I-type effort that does not constitute work undertaken as part of a prior SBIR/STTR funding agreement. The feasibility study shall demonstrate in their proposal that they have already achieved quality thermoplastic composite consolidation using their proposed process on a small or mid-size (up to 3 feet by 5 feet) part. The contractor shall also discuss in their Ph II proposal the ability to scale up processing size to efficiently process larger composite parts (larger than 4 feet by 6 feet). The process proposed should have the capacity to tightly control temperatures over the size of a large component to provide for efficient heating and temperature soak during the material recrystallization process. The applicant(s) should have already demonstrated a non-autoclave technology that can rapidly process thermoplastic composite materials. The applicant(s) should have already demonstrated the ability to tightly control processing temperature for small and medium parts. PHASE II: During the Phase II project, the awardee(s) shall demonstrate the capacity to process larger thermoplastic components which are at least approximately 4 feet by 6 feet on a relevant aerospace part. The awardee(s) shall validate that the proposed process results in a high fiber volume (58 percent+), low void (greater than 1.5 percent) thermoplastic part. The awardee(s) shall demonstrate that the process has a high level of thermal control over the entire size of the part with the ability to tightly control the material recrystallization process and optimize thermoplastic material properties. The awardee(s) shall validate part quality by performing a limited number of appropriate tensile, compression and short beam shear tests using relevant ASTM standards. The awardee(s) shall document the part preparation and processing time using the proposed process and compare the overall cycle time, cost, and weight of the part compared to a hand lay-up thermoset part processing using autoclave technology. The awardee(s) shall document tooling costs and lead times for the proposed processing technology compared to traditional thermoset tooling. PHASE III DUAL USE APPLICATIONS: The awardee(s) will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. The awardee(s) shall develop and demonstrate the ability to scale up their process for a variety of part geometries and sizes. The awardee(s) will work with relevant aircraft designers to meet their material performance requirements and demonstrate the applicability of the proposed process for large composite parts. REFERENCES: 1. https://www.energy.gov/sites/prod/files/2019/07/f65/Projects19%20-%20Energy%20Efficient%20Thermoplastic%20Composite%20Manufacturing_Boeing.pdf KEYWORDS: Large scale thermoplastic processing