Research & Development Div.
Composite Storage Module Phase I Program
Customer: Office of Naval Research (ONR)
The primary objective of this program is to produce a CSM as a temporary
attachment to a submarine for trials and evaluation of its suitability for
SEALS SPECWARFARE. The purpose of the CSM is for dry storage of
SEAL’s equipment for nesting in the ADVANCED Sail being developed for
the Virginia class submarine. Under the program, Production Products was
responsible for the development and demonstration of filament wound thicksection, composite technologies from concept/design stage to fabrication
stage.
Two carbon/epoxy 30 inch diameter thick Composite Storage Modules
(CSM) were designed and filament wound. One CSM incorporating integral
end domes was designed for concept validation to be tested at Naval Surface
Warfare Center – Carderock Division (NSWC-CD). The second CSM was
designed to incorporate a door and will be used for system evaluation by the
Navy.
Research & Development Div.
Composite Storage Module Phase 2 Program
Customer: Office of Naval Research (ONR)
Production Products was also responsible
for the substructure fabrication and
assembly for the 48 inch diameter
thermoplastic CSM. The substructure
included carbon/epoxy resin transfer
molded I-stiffening segments, AS4/3501-6
flange straps, and titanium splice plates.
And finally, the AS4/PEEK thermoplastic
joint specimens to verify the joint on the
48 inch diameter thermoplastic CSM were
fabricated and assembled at Production
Products.
Research & Development Div.
Composite Storage Module
Contracted Research with Office of Naval Research (ONR)
The objective of the program is to develop a Storage Module,
that can be fitted to the deck of a submarine, capable of
holding the mission equipment that a Navy Seal team would
deploy with. The current Storage Module is made of steal and
Is heavy, it severely affects the performance the performance
of the submarine. The Storage Module developed in this program
Is made of carbon fiber eliminating the performance problem.
688 Los Angeles Class Submarine
With Storage Module Installed
Navy Seal Storage for Mission Equipment
Location: Outside of Submarine Designed to
take Depth Pressures and to Be Light Weight
1200 Pounds of Filament Wound Carbon/Epoxy
Research & Development Div.
Liquid Molded Composite Armor Smart Structures Using Embedded Sensors
Customer: ARL “Army Research Laboratory” SBIR Phase 1
Under the Phase I program, Production Products
demonstrated that both Bragg Grating fiber optic sensors and
fluorescence optrode cure sensors could be used for cure
monitoring, measuring dynamic response, strain, and
structural health monitoring of resin infusion molded
composite structures. In Phase I we developed low cost
techniques to place the fiber optic sensors in the liquid molded
(resin infusion molded) composite structures; fabricated
representative Army composite armor components (1” thick
panels); performed cure monitoring using embedded Bragg
Grating and Fluorescence Oprode sensors;
performed
structural tests (4 point bending, impact, and 4 point bend
after impact) on components to demonstrate the ability of the
fiber optic sensors to accurately measure strain; and tracked
costs to show the impact on overall system cost of
incorporating smart structures in armor components.
Preform being manufactured
Sensor Lead Egress
Fiber Optic Brag Grating Sensors
being installed in the Preform
Fiber Optic Sensor Test Setup
Static Panel Test in a 700 ton press
Research & Development Div.
Liquid Molded Composite Armor Smart Structures Using Embedded Sensors
Customer: ARL “Army Research Laboratory” SBIR Phase 2
In the Phase II program, we developed an integrated, embedded,
distributed fiber optic sensor system, demodulation system, and
modeling and simulation based software system to provide real time
engineering data on cure monitoring and health monitoring. The
cure monitoring focused on Fluorescence Optrode Cure Sensors
(FOCS), both single, three axis, and multiple sensors on a strand
Bragg Grating Sensors, and SMARTweave. The Bragg Grating
allows axial strain, transverse strain, and strain gradient
measurements both during cure and in service for health monitoring,
including high dynamic rate loadings, such as low velocity and
ballistic impact. All sensor systems that were developed allowed for
simultaneous measurement of strain and temperature. We utilized
the Vacuum Assisted Resin Transfer Molding (VARTM) Liquid
Molding Process. We also demonstrated that Bragg Grating fiber
optic sensors could be used for detection and identification of ballistic
events in thick walled composite structures, such as tank walls.
Composite Load
Cell Containing
Bragg Grating
Sensors
VARTM of Panels
Containing Bragg,
FOCS, and
SMARTweave
Impact Test on
VARTM Panels
Research & Development Div.
Liquid Molded Composite Armor Smart Structures Using Embedded Sensors
Customer: ARL “Army Research Laboratory” Contracted Research
Dual 10 MHz Detector Unit
Beam Splitters
Grating Filter
Detector
Light Source
Ballistic Impact Panels
Static and Dynamic Testing of
The Horsetail Falls Bridge, a
Commercial Demonstration of
Technology Developed Under
this Phase 2
High Speed Demodulation Equipment
Research & Development Div.
Smart Tank Armor with Army Research Laboratory
Liquid Molded Composite Armor Smart Structures
Using Embedded Sensors (Phase I and II SBIR)
Fiber Optic Sensors Embedded in
Thick Section Composite Armor of Tank
• Intelligent Processing of Thick Composites
• Identify Area of Damage and notify
the Tank Crew
Sensors Used for Static
and Dynamic Testing of the
Horsetail Falls Bridge, WA
Research & Development Div.
Design & Develop F22 Nose Boom
Customer: Lockheed Fort Worth Tx.
F22 Raptor Air Superiority Fighter
F22 Light Weight Carbon Fiber Nose Boom
Production Products was subcontracted to
Lockheed Fort Worth for the development and
fabrication of filament wound Nosebooms for the
F-22 and Joint Strike Fighter (JSF). These
programs involved process development, tool
design, process specification, tooling fabrication,
and fabrication of four Nosebooms for the F-22
and two Nosebooms for the JSF. The advanced
filament winding process has been tailored for
utilization of advanced materials and high
modules carbon fibers. The four nosebooms for
the F-22 and two nosebooms for the JSF have
been completed, delivered to Lockheed, and
installed on the aircraft. They met all customer
requirements and are currently in use on the
flight test aircraft.
Nose Boom during
Machining Process
Nose Boom being Filament Wound
Research & Development Div.
Affordable High Performance Reinforced Polyurethane Shock and Vibration Mount
Customer Naval Surface Warfare Center - NAVSEA SBIR Phase 1
The objective of this SBIR is to develop a low
cost high performance generic elastomeric
machinery mount system which has varying
static and dynamic vibration properties to
provide vibration and shock isolation over a
wide operating load range. These mounts will be
capable of meeting performance specifications
for several mounts / load ranges as given in MILM-17185 (General Mount Spec.), MIL-M-17191
(P-Type Mounts), MIL-M-17508 (E-Type
Mounts), MIL-M-19379 (M-Type Mounts), MILM-19863 (5B5000 Mounts), and MIL-M-21649
(5M10000 Mounts). A reinforced polyurethane
shock and vibration mount system configuration
was designed, a prototype was fabricated using
resin transfer molding and vacuum resin
infusion, and its shock and vibration
performance was analytically predicted, and
tests were performed to demonstrate its ability to
meet those analytical predictions.
In Phase II we are transitioning the analytical
and experimental findings of Phase I into a
second generation prototype mount concept for a
family of mounts. We will design, fabricate, and
characterize the static and dynamic properties of
these mount concepts. Production Products will
manufacture mounts for sea trials by the Navy
and for commercial applications.
5MMPH120 Mount
5MMPH700
Mount
Research & Development Div.
Shock & Vibration Mount for Equipment and Pipe Hangers
Affordable High Performance Polyurethane Shock and Vibration Mitigating Mounts
(Phase 2 SBIR) Naval Surface Warfare Center – Carderock Division
Mounts are used by the Navy to protect equipment on ships and
Submarines and to help lower the noise signature of the vessels.
•The Goal of program was to develop a mount that had constant
frequency and consistent shock and vibration performance over a
large load range to reduce inventory requirements and to extend the
life of the parts.
•Numerous polyurethane materials were studied and mounts
underwent
Military specification mount testing.
The PP mount operates at
5Hz over a 0 to 450
pound range and one size
replaces the current
inventory of over 30 sizes
in this load range.
The PP designed mounts meet
the Navy’s 2000oF Fire requirement
Research & Development Div.
Non-Invasive Communication with Embedded Sensors in Composites
Customer: DARPA “Defense Advanced Research Project Agency” SBIR Phase 1
The objective of this program was to
investigate the use of fiber optic sensor
technology for monitoring composite
structures. The sensor system was
identified and tested in a composite
utility pole demonstration article.
The article was a modular, tapered glass/
epoxy utility pole that had Bragg Grating
Fiber Optic Sensors embedded in it.
Pole being manufactured with
embedded sensors
Physical Property Testing
Modular Construction
The joint of the pole was tested in three point bend
to verify it's ability to meet the requirements of a 40
foot long pole. The utility pole concept exceeded
the requirements of the customer and a Phase II
program was awarded.
Light Weight Adjustable Tooling
Modular Test Article
Research & Development Div.
Non-Invasive Communication with Embedded Sensors in Composites
Customer: DARPA “Defense Advanced Research Project Agency” SBIR Phase 2
This is a Small Business
Innovation Research Phase II
Program
that
Production
Products was contracted by
Defense
Advanced
Research
Project Agency. The contract was
completed 30 December 1997.
The objective of this program was
to investigate the use of fiber
optic sensor technology for
monitoring composite structures.
The program identified low cost,
highly reliable sensor systems
and manufacturing processes to
allow for economic/widespread
use
in
composite
DOD
application as well
as civil
Pole, driven with pile driver,12’
structure applications.
This into frozen ground with no damage
system was identified and tested
in a composite utility pole In Phase I of the program, the
demonstration article.
demonstration article was a
modular, tapered glass/epoxy
utility pole test article that had
Bragg
Grating
Fiber
Optic
Sensors embedded in it.
The
joint of the pole was tested in
three point bend to verify it’s
ability to meet the requirements
of a 40 foot long pole. The utility
pole concept exceeded the
requirements of the customer and
Installed Fiber Optic Sensors
a Phase II program was awarded.
In Phase II of this SBIR,
Production
completed
the
development and qualification of
a low cost fiber optic Bragg
Grating demodulation system and
a modular composite utility pole.
We have designed and fabricated
Education Kits for working with
Bragg Gratings and demodulating
the signal. We have designed
and fabricated Stand Alone Units
of the Bragg Grating Demodulator
for demodulating high speed
changes in longitudinal strain or
temperature events.
We have
also designed, fabricated, and
qualified a 65 foot long modular
composite
utility
pole
that
directly meets the needs of the
Utility Industry as well as the
DoD, including the Army Corps of
Engineers.
The poles have
undergone
environmental
qualification tests as well as
structural tests and currently are
being outfitted for field testing by
Amaron UE. The pole developed
is a unique, modular, filament
wound, composite pole design
which is very lightweight (9-13%
of a comparable size wood pole
weight).
65’ Pole being tested
The Pole is affordable, durable,
environmentally far superior, and
offers
significant
operational
advantages because of it’s
lightweight, modularity and long
life.
The unique modularity
feature
allows
reduced
stockpiles, easy handling with
smaller
work
crews
and
equipment,
and
simplified
installation and repair.
Pole passes class 1 test
for Utility Poles
Research & Development Div.
Modular 65’ Composite Utility Pole
Non-Invasive Communication with Embedded
Sensors in Composites Program (Phase I and II SBIR)
Advanced Research Project Agency (ARPA)
85% Lighter Than Wood
Nonconductive, Non-corrosive, Nontoxic
Resistant to Animals and Birds
Resistant to Air Pollutants
Cost Competitive for over 40’ poles
Low Cost Filament Winding
Modular for Easy Handling
Benign Failures – Tested at Production Products
Smart Sensor Tailorable
Pile Driven in Frozen
Ground
1200 Pounds Deflection
Filament Wound Construction
allows the fieres to be oriented
go give maximum strength
Deflection at 2812 pounds
Research & Development Div.
Low Cost Composite Manufacturing of Large Scale Hydrodynamic Surfaces
Office of Naval Research (Phase I STTR)
In this program Production Products and our Partner
University of Delaware developed a low cost vacuum
assisted resin transfer molding (VARTM) composite
fabrication technique and a design for a dimensionally
critical hydrodynamically smooth rudder for Naval vessels.
A ¼ scale twisted composite rudder, designed under the
program, was successfully fabricated using the newly
developed VARTM process. The rudder is approximately
42” from leading to trailing edge, 38” high, and
approximately 5” thick at the thickest section. The
structure is composed of a balsa core CNC milled to the
rudder shape, unidirectional glass cloth, and Dow
Momentum 411-350 vinylester resin.
Research & Development Div.
Filament Wound “Tuning Fork Housing” for Submarine Sonar Towed Array
Developed for Lockheed to be used on the Los Angeles Class Attack Submarines
Towed Array Deployed
Los Angeles 688 Class Submarine
The objective of the program was to develop a housing with
zero void content to house the Tuning Fork on the Advanced
Towed Sonar Array (voids distort the signature quality). This
Array is capable of detecting ships at a distance of over 1000
miles. The Array is extended from the rear of the submarine
and is 1.25 miles in length.
Research & Development Div.
SOCOM Mark V Advanced Composite Canopy
Contracted Research with the Office of Naval Research (ONR)
The objective of the program was to develop a light
Weight, high strength composite forward canopy
combined with a soft rear canopy that was capable
of providing Chemical/Biological protection to the
crew members.
SOCCOM Mark V
Research & Development Div.
Chemical/Biological (CB) Protected Mobile Maintenance Shelters
Air Force Research Laboratories USAF/AFMC (Phase I SBIR)
In Phase I, Production Products developed the design concept for the CB Maintenance Shelter (CAB-MS). This
shelter enables Air Force ground crews to service fighter aircraft in a mobile enclosure that can be quickly positioned
to allow the aircraft to be parked in an environment that is protected from Chemical and Biological (CB) contamination.
For this design, the aircraft will fit completely into the shelter. This design allows for incorporating a CB resistant
shelter material, CB overpressure filtration unit, recirculation filtration unit, HVAC equipment, closures, and adaptable
hydraulic ballast interfacing mechanism to seal to the tarmac or floor making the shelter airtight and able to be overpressurized. The shelter also contains a main aircraft door, an airlock for personnel entry and exit, windows, lighting,
power outlets, and structural airbeams. To demonstrate the feasibility of the CAB-MS Concept, subscale test
components were fabricated and pressure tested. The units were used to verify the adaptive seals ability to seal the
shelter when subjected to overpressure. The test results approached the target operation pressure of 0.5 iwg.
The second test shelter was able to reach .45 iwg. There are still some design changes that need to be made to minimize
leakage at the seal of the shelter to the tarmac, but Phase I verification testing proved the concept viable for use as the
CAB-MS. In the Phase II program, the necessary design changes will be incorporated into the full scale system and it
will be prototyped and tested for verification.
Research & Development Div.
Light Weight Bump Through Door System for Military CB Protective Shelters
Air Force Directed R&D Program
The Goal of the program was to develop a Bump “Through Door System” for use
in current CB protected shelter systems that is light weight, provides an effective
seal to prevent excessive leakage, and easy to install & use.
Reduced Weight
Reduced Pack Volume
Improved Transportability
Reduced Leak Rate
Tested to Meet Rigid
Military Specifications
Light Weight Composite
Construction
Research & Development Div.
Elimination of Wood Dunnage in ISO Containers and Combat
Ship Cargo Holds (Phase I SBIR) FISC Norfolk
In Phase I, Production Products worked on developing a bracing system to
reduce the huge TOC associated with blocking and bracing ordnance loads
for intra-station and over-the-road land transportation and stowage aboard
CLF ships. In this program we developed innovative advanced composite
structural concepts to provide a bracing system that will be launched off of
the existing legacy CLF fleet ordnance cargo hold track system and the floor
to ceiling stanchions. No alterations are required to the metal tracks, and
there is no reduction in the capabilities of the present system as in
accommodation of varied cargo sizes and shapes.
We also developed and
demonstrated a hard surfaced airbag system to replace dunnage used during
land transportation of cargo. This low cost concept is applicable to the ISO
containers to allow intermodal shipping of the cargo with no damage to the
cargo during truck to rail transfer and vice versa.
Hard Surface Airbag System
Shipboard Reusable Dunnage System for Ship Holds (SRDS)
Research & Development Div.
Affordable Polymeric Composite Material & Synthesis Program
Customer: DARPA “Defense Advanced Research Project Agency”
Fiber Optic Sensors
being installed
12” Carbon Fiber Tube
The Defense Advanced Research Project Agency (DARPA), contracted Production
Products to develop an intelligent manufacturing process for the manufacture of
affordable large polymeric composite structures. The goal of the Production Products
portion of the program was to develop concrete filled composite wrapped tubes that are
structural for increasing the strength of concrete bridge structures. The first set of
deliverables were filament wound tubes (2” dia. x 4” long) (glass and carbon/epoxy) for
material characterization studies of the composi-wrap process. The tubes were filled with
concrete and compression tested, at Washington University, to determine the optimum
specimen configuration and to verify the process. The composi-wrap specimens were
able to achieve a ten fold increase in compression strength over the concrete only
specimens. The second set of articles fabricated were much larger (12” diameter x 8’
long). These were filament wound with carbon/epoxy and embedded with Bragg Grating
Fiber Optic Sensors using techniques developed by Production Products. Washington
University filled them with concrete. The flexure specimen (12” dia. x 8’ long) were tested
at Washington University and the compression specimens (12” dia. x 2’ and 4’ long) at
University of Illinois. The strain measurements from the sensors were monitored by NRL.
At completion of this program, the Composi-wrap Process was verified and modeled and
is currently being planned for production bridge programs. Also, the use of fiber optic
sensors in civil structures was proven and shown to be amenable to composite
processing.
University Of Illinois
3,000,000# Press
The 4’ Concrete filled Carbon
Tube did not fail
2” Sample FW Tubes
Flat Panel Fabrication
Typical Failure of Composite
Wrap Concrete Filled Tubing
Research & Development Div.
Elastomeric Composite Bumpers
Customer: NSWC “Naval Surface Warfare Center” SBIR Phase 1
Bumper being manufactured
In this program Production Products is
under contract to Naval Surface Warfare
Center - Carderock Division to design and
develop novel marine impact bumpers for
dual use military and commercial markets
using highly abrasion resistant and damage
tolerant elastomeric matrix composites.
These materials have unique properties with
significant potential for use in impact
applications including bumpers for ships,
moorings in shipyards and commercial
marinas.
Finished Bumper
In Phase I we have designed, manufactured,
and structurally evaluated a new elastomeric
matrix composite (EMC) bumper system with
significantly improved energy dissipation
and the ability to minimize loading on a ship
hull during docking.
Multiple energy
absorbing systems including the EMC
bumper
structure,
the
pneumatic/foam/hydraulic system in the
bumper, and supporting tension tubes can
be engineered for any bumper design
requirements to produce an optimum load
stroke curve.
In Phase I, we have
demonstrated the potential for improvement
in energy absorption capability with our
prototype over conventional systems.
Life Cycle Test Stand
Bumper during Life Cycle Test
In Phase II, we will be tailoring the design of
the EMC bumpers to meet any bumper
design requirements with the load stroke
curve optimized and hull load minimized. We
will
then
design,
manufacture,
and
structurally evaluate a full scale EMC fender.
These full scale articles will also undergo
structural and marine field tests to qualify
them for commercialization.
Bumper Compression Test
Research & Development Div.
Elastomeric Composite Bumpers
Customer: NSWC “Naval Surface Warfare Center” SBIR Phase 2
In Phase II, we have tailored the design of
the EMC bumpers to meet any bumper
design requirements with the load stroke
curve optimized and hull load minimized.
We have designed, and manufactured, and
structurally evaluated two versions of the
full scale EMC fender. The full scale testing
proved successful and the articles are
awaiting structural and marine field tests to
qualify them for commercialization.
Research & Development Div.
Composite Wicket Gate Program
Customer: US Army Corps of Engineers
Production Products was subcontracted to
McDonnell Douglas on this program, which is
sponsored by the Army Corps of Engineers.
Under this program the first prototype composite
wicket gate was developed and fabricated for
test in the Ohio River. Production Products
performed final assemble and delivery of the
gate. This program is a prime example of a
cost effective application of composites in civil
structures.
Handling, machining, drilling,
adhesive bonding, assembly, and inspection of
large (nine feet by twenty-five feet) composite
structures was demonstrated by Production
Products.
Wicket Gate during assembly
Wicket Gate Installed in
Ohio River
Wicket Gate installation
Wicket Gate During Transport
Gate Actuator
Research & Development Div.
Affordable Tooling for Composite Structures
Customer: Wright Paterson Air Force Base STTR Phase 1 and 2
Under this program Production Products and Southern
Research Institute developed composite processing tools
and tooling approaches that offer lower cost and shorter
fabrication lead times with adequate durability and
thermal performance characteristics. We focused on a
novel localized resistive heating concept which applies
heat only to the part being processed and does not heat
the tool except at the tooling surface. Tooling costs have
been identified as a high cost area especially in the
prototype environment and as production rates continue
to drop. Our composite tooling approach produces
dimensionally accurate parts, (match the coefficient of
thermal expansion (CET) of the composite part), is
affordable to demonstrate the tooling approach in the
prototype environment, and is durable enough to meet the
requirements of production use. In Phase I we provided a
description of the tooling approach, preliminary designs
of the tooling system, thermal analysis of predicted
thermal performance, and cost analysis of anticipated
tooling fabrication costs. We resin transfer molded an F18 Wing Seal as the demonstration component. In Phase
II we designed fabricated and evaluated a resin transfer
molding tool heated with the resistive heating technology
for a sine wave spar. The resistive heating technology
proved very successful with rapid, consistent heat up of
the tooling surface and energy efficient and safe
processing. However, some additional development in the
ceramic tooling needs to be studied to make large complex
tooling surfaces more durable during tool disassembly.
Sine Wave Spar
Rear View of Prepreg Stiffiners
Resistively Heated
Sine Wave Spar Tool
Carbon Fiber F18 Rear Wing Seal
Research & Development Div.
Manufacture of Advanced Composite Submarine Structures (MACSS)
Customer: DARPA “Defense Advanced Research Projects Agency”
Production
Products
was
subcontracted to McDonnell Douglas
on The Manufacture of Advanced
Composite
Submarine
Structures
(MACSS) program, which is part of the
Advanced Research Projects Agency
Maritime Systems Technology Office,
Submarine Technology Program. The
program developed the material
product
forms,
processes,
and
equipment for automated fabrication
of low cost composite submarine
structures. These developments were
demonstrated through fabrication and
test of subscale components of the
Man Rated Demonstration Article
(MRDA).
Production Products is
involved in filament winding of
thermoset composite hull structures
in this program.
Compression After Impact
Specimen
Structural Test
Carbon/Urethane Part
Being Manufactured
Completed Sub-Scale Hull
Section with tooling
In this portion of the program, carbon fiber reinforced polyurethane is
being studied for its acoustic dampening characteristics as well as its
structural performance. Lamina material characterization specimens have
been fabricated (4” diameter JANNAF specimens) and tested. The filament
winding process parameters have been optimized for the urethane and a 2’
diameter by 5’ long by 0.25” thick laminate characterization cylinder has
been fabricated.
Furthermore, several Compression After Impact
Specimens were fabricated using vacuum assisted RTM and tested to
determine the ability of the glass fiber reinforced polyurethane to act as a
boundary layer and absorb some of the impact energy, thereby, lessening
the impact damage on glass/vinylester specimens.
Research & Development Div.
Low Cost, Out-of Autoclave Composite Manufacturing Process
Customer: NASA “National Aeronautical Space Administration” SBIR Phase 1
This is a Small Business
Innovation Research Program that
Production
Products
was
contracted by NASA Langley. The
objective of the program was to
perform a study of thermoset
composite
materials,
out-ofautoclave
manufacturing
processes, tooling concepts, and
equipment, which will then be
developed and productionized to
provide NASA and our military
and commercial customers with
low cost, high performance
composite structures. We utilized
thermoset resins which could be
cured at low temperature and with
novel processing methods.
Part being manufactured with RIH Process
Resin Injection Head Installed
Material Feed System
Resin Injection Head
We outfitted our McClean Anderson 6 Axis
filament winding machine with a resin
injection system that will allow for minimized
resin scrap during filament winding, will
improve the resin wet-out of the tow, and will
allow for resin cure advancement to minimize
part processing time and optimize ply
configuration possibilities.
Furthermore,
material scrap will be minimized, ply
orientation will be more controlled, and cure
time will be decreased.
We also
demonstrated cure advancement of the
material prior to winding onto the mandrel,
decreasing the processing time required to
cure the parts.
Research & Development Div.
Composite Scrap Reclamation Program
Customer: US Navy
Scrap Material from Boeing
Production Line Being Separated
Regrind Station
Under the Program Production
Products was tasked by the Navy to
develop a process to take uncured
composite material and recycle it.
Carbon Prepreg was collected from
the Boeing St. Louis composite
department
and
shipped
to
Production Products. The material
was taken directly from the “trash
cans” in Boeing’s composite area, no
special attempt was made to keep it
clean. In addition to contamination
the material was in various stages of
curing since it was not kept
refrigerated. We developed a matrix
which dictated the process under
which the material could be used.
Parts
were
successfully
manufactured for the Apache Ground
Support Kit, and Housings for control
panels.
Scrap Reclamation Production l line
Demonstration Tooling & Part
Made from Recycled Material
Research & Development Div.
Alternate Heating Technology for Thermoplastic Composites & Adhesive Bond Processing
Customer: ONR “Office of Naval Research” SBIR Phase 1 & Phase 2
In Phase I Production Products Manufacturing & Sales
(PPMS) has developed focused / directed energy heating
techniques for the processing of thermoplastic
composites and adhesive bonds with the support of our
subcontractor Southern Research Institute (SRI) and
our aerospace mentor McDonnell Douglas Aerospace.
SRI’s Development of graphite fabric heating elements
has broad applicability to low cost integrally heated
tools, thermoforming cells and filament winding as
demonstrated by PPMS and SRI in Phase I. Use of
directed energy to heat only the polymer in the
composite or the bond line eliminates the need for
expensive, high-temperature bagging materials,
sealants, tooling, and equipment and also allows
thermoplastic bonding/repair with low temperature
substrates, such as epoxy matrix composites or
aluminum. In Phase I, Production Products has
demonstrated the feasibility and physics understanding
of directed energy heating for thermoplastic composite
and adhesive bond processing.
In Phase II we
demonstrated scale-up of these fabrication methods in
fabrication of a thermoforming tooling cell for
fabrication of a thermoplastic Navy Director Room
Hatch. Also, an integrally heated filament winding tool
and filament winding tow-heating head was developed
for fabrication of a filament-wound thermoplastic
composite Advanced Amphibious Armored Vehicle
Drive Shaft.
Thermoplastic Oven Enclosure
IR Camera Monitoring
Cure Cycle
ATBW Advanced Technology
Bun Warmer
Integral Heated Thermoplastic
Tooling in operation
Thermoplastic Fiber Placement
Component Being Manufactured
Research & Development Div.
Low Cost Titanium Tow Bar
Customer: TACOM “US Army Tank Automotive Command” SBIR Phase 1
Unmachined Tow Bar Lunett Assy.
This is a Phase I and Phase II SBIR funded by the Army
– TACOM. In Phase I Production Products designed,
developed, fabricated, and structurally evaluated a lowcost titanium alloy tow bar which is significantly
lighter, more durable, and corrosion resistant
compared with the new M1 steel tow bar. Production
Products was assisted in design of the tow bar and
commercialization of the technology for the DoD, truck
and automobile industry by our subcontractor Holland
Hitch, who is the largest manufacturer of truck landing
gear and coupling devices in the world. During Phase I
Production Products evaluated designs for the tow bar
based on both Ti-6A1 4V and the new low-cost titanium
alloy TIMETAL 62S which has very high specific tensile
strength and modulus, outstanding fatigue strength,
notch sensitivity, and corrosion resistance.
Alternate manufacturing processes, joining processes, post
processing, material properties and cost were evaluated. Tradeoff studies were conducted to select the most cost-effective
solution meeting the 60% weight savings goal. A novel one
piece extruded titanium tube design was selected since this
design eliminates the welded-on machined end fittings and was
more cost-competitive with the baseline steel tow bar. Available
Ti-6Al-4V titanium tubing from TIMET was utilized in Phase I, with
the potential for use of TIMETAL 62S in Phase II. The final
titanium design incorporating lessons learned from Phase I
weighs 140 pounds, (200 pounds, 59% less than steel), and will
be durable, damage tolerant, corrosion resistant, and have
outstanding fatigue strength. The Phase II program, which we
are 4 months into, will include optimization of M1 titanium
towbar design, fabrication, lab and field testing.
Finished Lunett
Complete Titanium Assy.
Research & Development Div.
Low Cost Titanium Tow Bar
Customer TACOM “US Army Tank Automotive Command” SBIR Phase 2
This was a Phase II SBIR funded by Army
Tank- Automotive and Armaments Command
(TACOM). In Phase II Production Products
designed, developed, fabricated, and structurally
tested a low-cost titanium alloy tow bar which is
significantly lighter, more durable, and
corrosion resistant compared with the new M1
steel tow bar. During Phase I Production
Products evaluated designs for the tow bar based
on both Ti-6A1 4V and the new titanium alloy
TIMETAL 62S.
Alternate manufacturing
processes, joining processes, post processing,
material properties and cost were evaluated.
Trade-off studies were conducted to select the
most cost-effective solution meeting the 60%
weight savings goal. A novel one piece extruded
titanium tube design, which eliminates the
welded-on machined end fittings, was fabricated
and tested in Phase I. The final titanium design,
which is a modular cast design incorporating
lessons learned from Phase I, weighs 140 pounds,
(200 pounds, 59% less than steel), and will be
durable, damage tolerant, corrosion resistant,
and have outstanding fatigue strength. The
modular cast tow bar components were Hot
Isostatically Pressed.
The tow Bar assembly
was successfully structurally tested and was
provided to TACOM for field evaluation.
Assembled Tow Bar
Cast Titanium Lunette
Cast Titanium Clevis
Tow Bar in Test Set-Up
Research & Development Div.