Novel Multifunctional Materials and Lightweight Structures for Improved Small Unmanned Aerial Vehicle (UAV) Mission Capability

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials;Renewable Energy Generation and Storage OBJECTIVE: Develop novel integrated multifunctional materials and lightweight structures to increase performance of small, unmanned aerial vehicles (UAVs). DESCRIPTION: UAVs play an increasingly important role on the modern battlefield. Computing hardware and mass manufacturing have made camera-equipped, man-portable UAVs readily available. In order to maintain a technical advantage and increase mission capabilities, the state of the art in small UAV design and operation must be advanced by the use of novel materials and structural concepts. UAV performance could be improved by consolidating functions through the use of multifunctional materials, or novel lightweight materials. Multifunctional materials are any material or structure that integrates two or more previously separate functions. Some examples include sensors, circuitry, antennas, batteries, fluid conduits, or actuators that are embedded within, comprised of, or make up structural members [Refs 1 4]. Lightweight materials are those that advance the state of the art by making use of novel lightweight/high-strength materials and manufacturing technologies, to ensure the final part meets or improves design performance requirements and service life. Some examples include novel applications of additive manufacturing, aerogels, graphene, carbon nanotubes, or other technologies to reduce aircraft weight while maintaining structural integrity. Proposed concepts should seek to advance the state of the art of the design and construction of Group 1 3 UAVs. New materials, technologies, or methods shall utilize novel multifunctional or lightweight/high strength materials and structural components to enable UAV designs with improvements in weight, range, and/or time on station as compared to those constructed from conventional materials. Proposed concepts should: Introduce new technologies, materials, or methods, which advance the state-of-the-art of UAV design through the use of multifunctional or novel lightweight materials. Avoid areas that have already been well-explored (e.g., using topology optimization to design single-function structure) without adding significant novel value. Be readily applicable to aircraft structural components. For multifunctional materials, present the expected net weight savings vs using commercially-available, single-function alternatives. For novel lightweight/high-strength materials, present comparison of the expected specific strength as compared to conventional metals/composites for aircraft structural components. Present analysis of the ease/feasibility of manufacturing of the concept. PHASE I: Demonstrate the proposed concept through laboratory bench testing and/or coupon testing, as appropriate. Develop material properties, based on proposed concept, for use in commercial finite element analysis tools such as ANSYS, ABAQUS, and so forth. Demonstrate the feasibility of the proposed concept by developing models to predict material behavior and model all intended functions of the concept (i.e., for multifunctional materials all intended material functions should be modelled). The Phase I effort will include prototype plans to be developed under Phase II. PHASE II: Expand on Phase I work to refine and further develop the original concept by creating and evaluating prototype parts or structures. Produce, in a production-relevant environment, a representative full-scale prototype part or structure and demonstrate its performance in a simulated or realistic environment. Identify and evaluate risks, roadblocks, and challenges of full-rate production. Specific target parts for weight reduction are to be provided as appropriate during this phase. PHASE III DUAL USE APPLICATIONS: Validate and demonstrate an aircraft-ready part as provided in Phase II. Develop solutions to the risks, roadblocks, and challenges of full-rate production as discovered in Phase II. Commercial demand for small UAVs is increasing as the technology becomes more mature. Industries such as farming, land management, and last-mile delivery are exploring or already using systems comparable to Group 1 3 UAVs. Materials or methods developed as part of this SBIR will have direct private sector commercial potential, as they would serve to increase the overall efficiency and capability of such systems. REFERENCES: 1. Asp, L. E., Bouton, K., Carlstedt, D., Duan, S., Harnden, R., Johannisson, W., Johansen, M., Johansson, M. K. G., Lindbergh, G., Liu, F., Peuvot, K., Schneider, L. M., Xu, J., & Zenkert, D. (2021). A structural battery and its multifunctional performance. Advanced Energy and Sustainability Research, 2(3), 2000093. https://doi.org/10.1002/aesr.202000093. https://doi.org/10.1002/aesr.202000093 2. Xu, J., Geng, Z., Johansen, M., Carlstedt, D., Duan, S., Thiringer, T., Liu, F., & Asp, L. E. (2022). A multicell structural battery composite laminate. EcoMat, e12180. https://doi.org/10.1002/eom2.12180 3. Shemelya, C. M., Zemba, M., Liang, M., Espalin, D., Kief, C., Xin, H., Wicker, E. W., & MacDonald, E. W. (2015, April). 3D printing multi-functionality: Embedded RF antennas and components. In 2015 9th European Conference on Antennas and Propagation (EuCAP) (pp. 1-5). IEEE. https://ieeexplore.ieee.org/abstract/document/7228805/metrics#metrics 4. Sairajan, K. K., Aglietti, G. S., & Mani, K. M. (2016). A review of multifunctional structure technology for aerospace applications. Acta astronautica, 120, 30-42. https://doi.org/10.1016/j.actaastro.2015.11.024 KEYWORDS: Unmanned Aerial Vehicle; UAV; Multifunctional; Material; Structure; Lightweight; Optimization