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DIGITAL LIBRARY: SAMPE 2019 | CHARLOTTE, NC | MAY 20-23

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Rapid High-Performance Molding (RAPM) for Small Parts

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Title: Rapid High-Performance Molding (RAPM) for Small Parts

Authors: Gail L. Hahn and Thomas K. Tsotsis

DOI: 10.33599/nasampe/s.19.1388

Abstract: RApid high-Performance Molding (RAPM) for Small Parts is a program under the Tailorable Feedstock and Forming (TFF) initiative of the Defense Advanced Research Projects Agency/Defense Science Office (DARPA/DSO) to revolutionize the cost paradigm for small composite parts enabling pervasive use in defense applications that are insensitive to part mix and rate fluctuation. Aerospace-capable, composite-material product forms and forming techniques inspired by industrial-automotive composite materials and manufacturing technologies are being developed by a Boeing-led team to achieve a reconfigurable manufacturing cell featuring modular tooling and rapid heating/cooling with pixelated zones to win design/manufacturing trades for composite small parts enabling transition of these technologies and their spinoff benefits across the supply network. Stakeholders are interested in improving “throughput” and gaining better understanding of small-part (and process) composite trade space and processing techniques for repeatable part quality. Defense customers are also interested in agility to deal with manufacturing rate because of the range of production quantities across defense applications and the frequent fluctuations in production/spares quantities across defense. Challenges, opportunities, and progress to date will be discussed for forming thermoset prepreg, thermoplastic prepreg, and resin-infused materials.

References: 1. Vandenbrande, J. “Tailorable Feedstock and Forming (TFF)” https://www.darpa.mil/program/tailorable-feedstock-and-forming 2. Gardner, G. “Turnkey Manufacturing Systems: Materials, Markets & Maturation” Composites World, January 2016 3. Gardner, G. “Plant Tour: Benteler SGL, Ort im Innkreis, Austria” Composites World, September 2017 4. Koon, R., Rademacher, M., and Getty, M. “Challenges and Opportunities to Transitioning Automotive Composites to Aerospace.” CAMX Conference Proceedings. Orlando, FL, December 12-14, 2017. 5. Yarlagadda, S., Deitzel, J., Heider, D., Tierney, J., and Gillespie Jr., J.W. “Tailorable Universal Feedstock for Forming (TuFF): Overview and Performance.” SAMPE Conference Proceedings. Charlotte, NC, May 20-23, 2019. 6. Tsotsis, T.K., Cespedes-Gonzales, G., Wiener, M., Cohen, L. J., Calamito, D., Costantino, S., and Klunker, F. “Fabrication of a Complex Part with Deep-Draw Sections by Resin Transfer Molding.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 7. Luchini, T.J., Rodriguez, A.J., Rogers, S.A. Bras, A., Whysall, A., Russell, R., Lucas, S., and Hahn, G.L. “Spring Frame Press Fabrication of Aerospace Production Components.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 8. Shewchuk, S.M., Halford, B., Matlack, M.P., Sharpe, A. and Massey, P. “Development of Scalable Dynamic Control Architectures for Flexible Composites Manufacturing Work Cells.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 9. Schell, J.J., Shewchuk, S. M., Leach, D., McCrea, T., Abrams, N., Postera, R., and Hahn, G. L. “Rapid High Performance Molding of Structural Thermoplastic Composite Parts.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 10. Charles, D.A., Matlack, M.P., Hahn, G.L. “Agile Analysis of Manufacturing Cell Costs for Molding of Small Composite Parts.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 11. Yarlagadda, S., Advani, S., Deitzel, J., Heider, D., Molligan, D., Roseman, D., Simacek, P., Tierney, J., and Gillespie, Jr., J.W. “Tailorable Universal Feedstock for Forming: Formability.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019.

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1388

Pages: 13

Price: FREE

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