N112-102 TITLE: Advanced Vacuum Bagging Technologies

TECHNOLOGY AREAS: Air Platform, Materials/Processes

ACQUISITION PROGRAM: F-35, Joint Strike Fighter

OBJECTIVE: Develop and demonstrate a multi-use vacuum bagging system that can be used for the autoclave and vacuum-bag-only curing of medium to large composite aircraft structures.

DESCRIPTION: The current fabrication and application of single-use, nylon vacuum bags is labor intensive and failure prone due to operator, size and configuration dependent variables. Current reusable bagging technology is costly and does not lend itself to more complex geometry typical of 5th generation and beyond aircraft. The use of reusable rubber vacuum bags has been only marginally successful in reducing costs. High fabrication and maintenance costs and bag shrinkage have limited its broader use. Cost effective methods, such as, but not limited to, the use of disposable liquid application rubber technologies, would address many of those cost and producibility related issues.

The technology developed must be compatible with today's generation of epoxy and bismaleimide materials. The technology must be environmentally friendly, non-contaminating, and capable of 375 degrees fahrenheit service, and should lend itself to application at the prime contractor and major composite part supplier facilities. Interaction with an aircraft composite structure manufacturer to assist in the transitioning of the concept to production applications is encouraged.

PHASE I: Identify, develop and prove feasibility of concept for advanced vacuum bagging material and system. Complete a preliminary analysis of environmental, and health and safety factors, identifying potential risks.

PHASE II: Produce prototype system and materials based upon the results of Phase I. Initial evaluation of the system may be performed by manufacturing flat composite items. Select a full-size, medium-to-large, complex aviation composite structure and demonstrate the prototype system. Refine analysis of environmental and health and safety factors initiated in Phase I. Develop return on investment (ROI) and verify process is robust and capable for composite production environments; establish facilities requirements, process flow and environmental requirements.

PHASE III: Finalize and transition production-ready bagging system and materials suitable for use in aircraft production. Finalize all environmental and health and safety factors.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The technology would have potential use in commercial aviation and wind power blade composite manufacturing.

REFERENCES:
1. Strong, A. B. & Ridges, M. (2005). Composites Manufacturing. "Will 'Spray On' Vacuum Bags Save the Aerospace Industry Millions". http://www.acmanet.org/cm/archive/may05.cfm

2. Gardiner Publications (Ed.) (2007). Composites Technology. "Reusable Vacuum Bags". http://www.compositesworld.com/products/reusable-vacuum-bags

KEYWORDS: composites bagging; vacuum bag; spray on bag; roll on bag; rubber bag; re-usable composite bagging

** TOPIC AUTHOR (TPOC) **

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