Low Cost, Light Weight Composite Structures Using the Quickstep Manufacturing Process Technology (PVCI-001) Navy SBIR FY2008.1 Sol No.: Navy SBIR FY2008.1 Topic No.: N08-030 Topic Title: Low Cost, Light Weight Composite Structures Using the Quickstep Manufacturing Process Technology (PVCI-001) Proposal No.: N081-030-1383 Firm: Vector Composites, Inc. 2000 COMPOSITE DR DAYTON, Ohio 45420-1493 Contact: David Sabol Phone: (937) 297-9433 Web Site: www.drtechnologies.com Abstract: Carbon fiber composite structures provide light weight and high performance solutions for military aircraft. Alternative Out-of-Autoclave (OOA) processes are needed to reduce manufacturing costs of composite structures and increase their usage for aerospace systems. Quickstep is a low cost alternative to autoclave processing, which uses large capacity fluid storage tanks and heat transfer fluids to directly heat the part and tooling and control temperature during processing, Quickstep can use either aerospace grade qualified prepreg materials or non-impregnated materials that are resin infused. The tool and part are encased to create a floating pressure equilibrium environment eliminating the need for tooling backing structures. A program is proposed to demonstrate low cost, lightweight composite structures using the Quickstep process as an alternative to autoclave processing for Navy system applications. In Phase I, sub-scale test articles will be fabricated using Quickstep and autoclave processes and tests conducted to demonstrate equivalent properties but lower cost of Quickstep. The Phase I option will study tooling materials and fabricate sub-element articles. In Phase II, Vector along with Boeing and the Navy will identify full-scale test articles to be fabricated and tested using the Quickstep process technology. Benefits: Lightweight composite structures reduce weight and system operational and energy costs for Navy and other aerospace systems. Low cost alternative manufacturing processes to autoclaves will result in increased usage of composites. Quickstep is expected to be lower in cost than autoclaves due to reduced cycle times for heating and cooling, reduced energy consumption, lower tooling costs, and lower capital investment costs. Larger parts can be fabricated using Quickstep compared to autoclaves. Materials qualification costs will be less since materials previously qualified in other processes can be used. Return