Novel Multi-scale/Multi-physics Integrated Tool for the Prediction of Manufacturing-Induced Defects in Autoclave Composite Airframe Parts Navy STTR FY2015.A Sol No.: Navy STTR FY2015.A Topic No.: N15A-T003 Topic Title: Novel Multi-scale/Multi-physics Integrated Tool for the Prediction of Manufacturing-Induced Defects in Autoclave Composite Airframe Parts Proposal No.: N15A-003-0085 Firm: Composites Automation LLC 9 Adelaide Court Newark, Delaware 19702 Contact: Roger Crane Phone: (410) 562-2163 Abstract: A multi-scale/multi-physics software will be developed to predict manufacturing-induced defects due to materials, parts, tools and processes. Potential defects include voids, ply waviness, delaminations, fiber wrinkling, resin starvation/rich areas, and distortion/warpage caused from tool-part interaction. .Analytical tools will be integrated into a commercial available finite element design and analysis suite to allow the evaluation of effect of these defects on the performance of complex geometries in real processing environments. This STTR will demonstrate the approach on autoclave processing and high-performance composites materials for aerospace structures but the methodology can be implemented for a variety of materials and processes. Benefits: Composites Automation LLC has partnered with the University of Delaware - Center for Composite Materials (UD-CCM) and ESI to incorporate UD-CCM's analytical composite design tools into ESI's Composites Simulation Suite. The proposed integrated software suite allows composites designers to take into account material and process variation and enable optimization of composite components at all levels. This improves design allowables, weight efficiency and manufacturing yield, and reduce risk and cost for existing and new composite components. Integrating the existing (and if necessary newly developed) analytical tools into a commercial software suite accelerates market acceptance and allows penetration beyond the aerospace segment. Return