Title: Encapsulated Low-outgassing Composite Manufacturing with Potential for On-orbit Demonstration

Authors: Chung Luen (Ivan) Wu, Usharee Perakalapudi, Morgan Scott, Zheyuan Zheng, Benajmin Ochs, Murphy Stratton, Logesh Shanmugam, Jeff Baur

DOI: 10.33599/nasampe/s.25.0158

Abstract: The future of space exploration requires a paradigm shift from deployable pre-manufactured structures to structures that are manufactured and assembled on-orbit. A demonstration of onorbit manufacturing of high stiffness carbon fiber composites is sought. However, space-based composite manufacturing is significantly constrained by launch volume, on-orbit processing energy and equipment, and off-gassing requirements. While others have used on-orbit thermoplastic additive manufacturing, this study investigates the processing and properties of encapsulated thermoset carbon fiber prepreg with the potential for on-orbit manufacturing of composite tubes. Specifically, we infuse catalyzed dicyclopentadiene (DCPD) resin into layered cylindrical carbon fiber preform sleeves, seal and encapsulate the prepregs between compliant and impermeable films, and then mold and cure the prepreg to rapidly produce a thin-walled, high-stiffness composite tubes using a low energy process with low outgassing. We demonstrate the scalability of tube prepreg by infusing a 10-foot long prepreg with industrial partners. Using flat surrogates of the cylindrical laminate, we demonstrate that the prepregs are stable and can be cured quickly (~ 5 minutes) and with only 11 psi (75.8 Kpa) of applied pressure to create composites with high (155-160°C), low voids (<1%), and low off-gassing (<1%). Initial promise is demonstrated for a future planned space demonstration on the International Space Station (ISS) through “Mission Illinois”.

References: 1. 2. 3. 4. 5. 6. 7. 8. 9. Larson, R., Bergan, A., Leone, F., Kravchenko, O.G.: Influence of stochastic adhesive porosity and material variability on failure behavior of adhesively bonded composite sandwich joints. Compos. Struct. 306, 116608 (2023). https://doi.org/10.1016/j.compstruct.2022.116608 Palmieri, F.L., Hudson, T.B., Smith, A.J., Cano, R.J., Kang, J.H., Lin, Y., Abbott, L.J., Clifford, B., Barnett, I.J., Connell, J.W.: Latent cure epoxy resins for reliable joints in secondary-bonded composite structures. Compos. Part B Eng. 231, 109603 (2022). https://doi.org/10.1016/j.compositesb.2021.109603 Smith, A.J., Salem, J.A., Hudson, T.B., Palmieri, F.L.: Interlaminar mechanical performance of latent-cure epoxy joints. Compos. Part B Eng. 255, 110567 (2023). https://doi.org/10.1016/j.compositesb.2023.110567 Hudson, T.B., Smith, A.J., McWeeney, N.J., Dolph, C.T., Kang, J.H., Cano, R.J., Palmieri, F.L.: Offset-stoichiometric reflowable composite bonding method with adhesive for mitigating strict faying surface tolerances. Compos. Struct. 351, 118636 (2025). https://doi.org/10.1016/j.compstruct.2024.118636 Hudson, T.B., Smith, A.J., Cano, R.J., Kang, J.H., Lin, Y., Palmieri, F.L.: In-situ inspection of reflowable-interface composite joints during cure in an autoclave. In: AIAA Paper 20211773. Presented at AIAA Scitech Forum. Virtual Event (January 11-21, 2021) Hudson, T.B., Baro, F., Smith, A.J., Kang, J.H., Cano, R.J., Palmieri, F.L.: Ultrasonic inspection during autoclave cure of reflowable-interface composite joints. J. Compos. Mater. 57, 3515–3528 (2023). https://doi.org/10.1177/00219983231188173 Cardona, A.M., Jegley, D.C., Lovejoy, A.E.: Manufacturing trials of integrally stiffened composite panels using automated fiber placement. Presented at the SAMPE Conference & Exhibition, Seattle, WA (April 17-20, 2023) Cardona, A.M., Anderson, E.K., Simmons, L., Larson, R.A., Mason, B.H., Tury, J.: Manufacturing of aircraft structures using composite tailoring techniques. Presented at the SAMPE Conference and Exhibition, Indianapolis, Indiana (May 19-22, 2025) Mason, B., Anderson, E., Cardona, A., Jutte, C., Larson, R.: Structural sizing of a towsteered truss-braced wing box test article. AIAA Paper 2025-0637. Presented at the AIAA Scitech 2025 Forum , Orlando, FL (January 6-10, 2025) 10. NASA ISAAC Fact Sheet, FS-2016-12-273, 2021

Conference: SAMPE 2025

Publication Date: 2025/05/19

SKU: TP25-0000000158

Pages: 13

Price: $26.00