Title: Optimized Prepreg Layup Techniques and Tooling for Building Light Composite Aircraft Fuselage Substructure

Authors: Stephen J. Pety, Paul B. Abitz

DOI: 10.33599/nasampe/c.24.0239

Abstract: The hand layup of composite prepreg is widely used to build aerospace parts. However, emerging markets such as high-performance business jets and Advanced Air Mobility (AAM) require the fabrication of complex part geometries that present quality concerns for layup. This paper discusses case studies on how to build complex fuselage substructure parts. We built parts with three demo geometries and evaluated them with non-destructive evaluation (NDI), dimensional inspection (DI), and micrographs. First, we built C-channel hoop frames in a female cure tool. We used optimized ply sizes, intensifiers, and custom vacuum bags to maintain ply orientation and radius quality. Second, we built double I-beams containing trapped geometry and T-flanges prone to springback from cure. We overcame these challenges with a multi-piece tooling suite that was compensated for springback via Finite Element Analysis (FEA). Third, we built pans with sharp corners and trapped geometry. We used a multi-piece tool for breakout and darting for the corners. These studies provide insight into tooling and layup strategies for complex composite parts.

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Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000239

Pages: 12

Price: $24.00