This proposal provides an innovative CH-53K cargo floor that will exceed all technical requirements by using in-situ automated fiber placement of thermoplastic composites along with optimized stringers to produce a cobonded floor structure. The design will take advantage of the superior damage tolerance of thermoplastic composites while stressing manufacturability and affordability. Stringer optimization will be conducted in the Phase I to improve load carrying capability resulting in a durable, lower weight cargo floor structure. Phase I Option will involve design, fabrication and testing of a subscale article. Proven in-situ cobonding will be used to bond the skin to stringers to overcome problems in previous programs. Phase II will consist of the design and development of a representative critical cargo floor system sections including a treadway section, roller section and walkway section for the CH-53K. The prototype floor sections will be evaluated through demonstration and testing under conditions representative of a military aircraft cargo environment.
Benefit: Automated Dynamics has a long history of commercializing technology developed through the SBIR program. Our core technology, in-situ fiber placement of thermoplastic composites, was developed with help of the SBIR program. This technology has resulted in the production of tens of thousands of composite parts resulting in millions of dollars of revenue over the years in a wide variety of markets and applications. The SBIR program has helped with the success and growth of Automated Dynamics, and will continue to be a key path for development of new products in the years to come. Automated Dynamics will pursue thermoplastic composite floor panel opportunities within the CH-53K program as directed by this SBIR topic. The CH-53K program presents a sizeable opportunity in and of itself to justify an SBIR topic, but the total available market for an innovative cargo floor system is much larger. There certainly exists many similar applications within military platforms such as the V-22, as well as other commercial rotorcraft and aircraft floor applications that demand lightweight and durable materials. In addition to aerospace applications, these cargo floor panels have an enormous potential in land vehicle applications including truck trailers, cargo containers, and railway cars.
Keywords: additive manufacturing, additive manufacturing, Composite Floor, Weight Savings, cobonded, Rotorcraft, Corrosion Resistance, Thermoplastic Floors
