Design and Manufacturing Process Automation for Next-Generation Composite Missile Canisters Navy SBIR FY2009.2 Sol No.: Navy SBIR FY2009.2 Topic No.: N092-141 Topic Title: Design and Manufacturing Process Automation for Next-Generation Composite Missile Canisters Proposal No.: N092-141-0664 Firm: KaZaK Composites Incorporated 10F GIll Street Woburn, Massachusetts 01801-1721 Contact: Tim Mustone Phone: (781) 932-5667 Web Site: kazakcomposites.com Abstract: Missile system combinations such as MK-21 / SM-3 have reached the total weight limit of ship-based launchers. Reduced canister weight would provide margin needed for increased encanistered missile performance without exceeding total system weight limits. KaZaK will work with Raytheon Missile Systems to design and demonstrate a replacement for MK-21, used with multiple sea-based missiles. Replacement of steel structure with more modern composites would save considerable weight. However, composite canisters made by more conventional manufacturing methods such as filament winding, braiding, VARTM, fiber placement or RTM would unacceptably increase cost. KaZaK propose to address both weight and cost while optimizing a form, fit and function composite MK-21 for pultrusion manufacturing. Pultrusion is a highly automated method for making constant cross section hardware at half or less of the cost of other composite manufacturing methods. In Phase I KaZaK will design pultruded composite corners, then test to verify they survive pressure loads resulting from missile launch. Our team will address multiple other design concerns including restrained fire, moisture permeability, and straightness associated with material transition from steel to composite. Phase I will conclude with confirming test results along with cost and performance predictions for a fully integrated composite MK-21 production unit. Benefits: Canisters are used to store, transport and launch current and emerging missiles. Canister weight is a major concern for mobile missile systems, including those used on Naval surface combatants. Weight can be significantly reduced by changing from steel to composite canisters. However, the current fiscal environment will not tolerate a cost increase to gain performance. To be widely accepted, new composite canisters will need to be made by the low cost pultrusion process, which automates production of constant section shapes. Successful completion of the proposed cost-effective pultruded composite MK-21 will enable widespread acceptance of the technology for application to many other Navy missile canister systems, and in addition those used for land-based mobile launches such as THAAD and PAC-3. KaZaK is already actively producing low cost composite missile containers and canisters for smaller missiles, and has also prototyped a PAC-3 pultruded carbon/epoxy shell. By working closely with Raytheon Missile Systems in Phase I and II development, KaZaK will have a ready path for a rapid transition to Phase III applications for multiple systems. KaZaK specializes in very large cost-effective high performance pultruded structures. Successful development and fielding of square missile launch canisters will open markets beyond the military for pultrusion of other large shell structures with weight and cost concerns, such as tractor trailers, ship structures, ISO shipping containers, and train car bodies. Return