Novel Prepreg based On-aircraft Repair (NoPORE) Navy SBIR FY2016.1 Sol No.: Navy SBIR FY2016.1 Topic No.: N161-017 Topic Title: Novel Prepreg based On-aircraft Repair (NoPORE) Proposal No.: N161-017-0310 Firm: Concepts to Systems, Inc. 500 Stinson Drive Danville, Virginia 24540 Contact: Leendert Hartoog Phone: (434) 217-5180 Abstract: A novel prepreg based on-aircraft repair technology is proposed. The C2Si team, with in-depth and hands-on complementary experience, will innovate on every aspect of advanced composite repair performed on-aircraft with limited equipment accessibility and short timeframe. Repair quality will be comparable and likely better than state-of-the-art (SOTA) materials and procedures. USC, as the subcontractor, brings in the unique prepreg format, superior cure chemistry resin and experience in out-of-autoclave, vacuum bag only low temperature SOTA process. Our team will bring in software implementable damage assessment and numerical analysis assisted damage area classification, repair area preparation, and laminated composite patch design process framework requiring workforce with only handheld equipment enabling reliable repair at the operation site. Our team will also demonstrate mechanical properties of the repair patch comparable or superior to AS4/EA 9390 resin wet layup double vacuum debulk processed panel. Successful completion of Phase I work will result in establishing feasibility of the NoPORE process and USCPreg based laminate meeting topic criteria at a proof-of-concept level. The end-to-end repair steps will be developed to follow in Phase II. Phase I will also demonstrate the relative advantages and process suitability of USCPreg based composite patch for on-aircraft repairs. Benefits: The proposed technology is not only going to revolutionize the infield repairs but can create a paradigm shift in the way composite structures are built. In addition to DoD, commercial airlines, buying newer aircraft with increased advanced composite material content, will be the potential and bigger commercial customers. C2Si is positioned to capture repair contracts for time critical on-aircraft repair with minimum infrastructure. Repair of damaged structural parts at takeoff/landing site is the first application. We will be working with both OEM and airline customers to ensure the long term commercial market in the maintenance and repair of composite and metallic assemblies. These repairs include flight control surfaces, radomes, landing gear doors, access covers, and doors. C2Si will pursue primary and secondary structure composite repair for the V-22, ATR 42/72, Saab 340/2000 ERJ 145/135 and Emb120, Canadair RJ, BAe 146, AvroRJ, Shorts, Learjets, Hawker, Dash-8 and Jetstream among others. The wind power industry is an emerging enormous market for on-location repairs. C2Si will start pursuing this market following Phase II. Other composite components that require repair include heavy truck front ends and other automotive as well as marine products. As CFRP moves into more critical structural components on the chassis, repair is likely to be more desirable in automobiles. Composites are increasingly being used to repair structures built with other materials, such as bridge beams, bridge decks, parking garages and pipelines, including underground systems. Composites also can be used to repair product pipelines, such as natural gas and petroleum pipes at oil refineries and offshore platforms, and to rehabilitate underground storage tanks without the time and expense of excavation. Return