Advanced Isothermally Produced Next-Gen Composites

Next generation aircraft are anticipated to be largely made with composite components, requiring significant increases in manufacturing rates of composites to meet the demand for a new fleet of aircraft. The higher rate manufacturing will require multiple advances, including rapid curing and lower processing temperatures. These requirements can be enabled by new processing methods such as isothermal rapidly cured composite parts. NASA has developed materials and methods that meet those stringent requirements for high-rate manufacturing. The innovators have demonstrated at least two families of new resin formulations that meet the expected high-rate manufacturing needs. These new formulations have been engineered to be infused and cured at the same (i.e., isothermal) temperature, below that of commercially available materials. The materials can then be removed from the mold while still hot without distorting the shape, thereby reducing the processing times by eliminating the need for cooling to occur in the mold. After a post-cure process - which takes 4 hours or less and can be performed in batches - the mechanical properties of NASA's next-gen composites. The related patent is now available to license. Please note that NASA does not manufacturer products itself for commercial sale. Next-generation composite aircraft that are produced at a high rate require fundamental advances in composite materials and manufacturing processes. Innovators at NASA Langley Research Center have developed a new family of formulations and composite processing methods that enable rapid and simpler fabrication of aerospace-grade composite materials. The key innovation is the combination of materials and methods enabling resin infusion and curing steps to occur at the same temperature, thus reducing the required processing time and simplifying the overall process. The new formulations developed by NASA have applications within next-generation commercial and military aircraft but may also be used in other applications including electric vertical take-off and landing (eVTOL) aircraft, automotive, and structural (terrestrial and in-space) uses if high mechanical properties and rapid manufacturing rates are required.