SBIR-STTR Award

Contractor will examine the feasibility of utilizing pultrusion-type continuous tape laying manufacturing equipment to fabricate composite sandwich structure wings and stabilizers for close range and short range class unmanned aerial vehicles. During Phase I a small proof-of-concept manufacturing machine will be designed, built, and evaluated. In addition, the quality of the manufactured product from the test machine will be evaluated. A feasibility report will be prepared. The proposed outcome for Phase I is an evaluation of the novel manufacturing machine, and of the resulting UAV wing material. In addition, if the development is promising, a preliminary design for a full-scale machine will be prepared. Further applications, commercial and government, include the full range of UAV platforms currently under development and in operation.

The purpose of this project is to continue the examination of the feasibility of UAV airfoil and control surface manufacturing machine fabricated that successfully produced standardized airfoil cross-section material. The purpose of Phase II is to build a full-scale prototype pultrusion manufacturing system for composite airfoil shapes. The full-scale machine would automate the manufacturing process and further improve the quality of the finished product. The overall design of the Phase II machine will emphasize an "open system" approach to facilitate continuous improvement, and to provide the flexibility necessary to accommodate a variety of designs and required materials. The Naval Research Laboratory FLYRT wing will be used as a production sample and aerodynamic data developed for the sample product. Also, stand-alone options to develop a platen and manufacture thick sectioned airfoils for an ongoing ARPA research project is proposed. Anticipated

Benefits:
Successful production of the FLYRT wing will benefit the ongoing NRL FLYRT project. In addition, material produced by the full-scale machine will be provided to UAV and other aerospace manufacturer for evaluation as to other potential applications. Also, production of an airfoil with a potential 50% thickness will be performed for an ongoing ARPA project.