Description: 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.

Benefits: 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.