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Generating Autoclave-Level Mechanical Properties with Out-of-Autoclave…

Award Information

National Aeronautics and Space Administration
Award ID:
Program Year/Program:
2009 / STTR
Agency Tracking Number:
Solicitation Year:
Solicitation Topic Code:
Solicitation Number:
Small Business Information
Accudyne Systems Inc
210 Executive Dr Newark, DE -
View profile »
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No
Phase 2
Fiscal Year: 2009
Title: Generating Autoclave-Level Mechanical Properties with Out-of-Autoclave Thermoplastic Placement of Large Composite Aerospace Structures
Agency: NASA
Contract: NNX09CB71C
Award Amount: $599,487.00


While in the 1970's and 1980's, composites were adopted for aerospace structure for increased performance and weight savings, the 1990's and 2000's witnessed the attention towards cost-effective fabrication. All thermoset processes that utilize such machines rely on autoclaves to consolidate the laminates, at significant acquisition and operational expense. Autoclaves to consolidate wings are hugely expensive. Autoclaves for fuselages are nearly cost-prohibitive (only one exists). Autoclaves for the Ares V do not exist. The marketplace would welcome a proven out-of-autoclave fabrication technology. The tasks in the ASI/UD-CCM STTR phase 1 was to assess the performance of the current TP-ATP heads, do a model based parametric study to determine possible head and process parameter changes and demonstrate an improved understanding of the head, with a goal of autoclave level properties. A set of models for the in situ Automated Tow/Tape Placement (ATP) processes that capture the important process phenomena were developed by UD-CCM. Accudyne then measured the laminate roughness, fabricated samples using a variety of conditions and tested the samples. Testing of the laminates indicate: placing with flat tape and using improved head chilling increases mechanical properties. Compacting with only a ýý load reduces properties. Using a vacuum bag oven reconsolidation is ineffective, and even reduces mechanical properties. The phase 2 program innovation is to develop and deploy University of Delaware process models to Accudyne's thermoplastic tow and tape placement head to remedy the mechanical property shortfall between the two fabrication processes used to manufacture large composite aerospace structure important to NASA. An additional advantage that would accrue by adopting TP-ATP would be the use of novel thermoplastic materials with thermal stability and toughness far in excess of what thermosetting materials can achieve.

Principal Investigator:

Mark Gruber
Principal Investigator

Business Contact:

Mark Gruber
Business Official
Small Business Information at Submission:

Accudyne Systems, Inc.
134 Sandy Drive Newark, DE 19713

EIN/Tax ID: 510373665
Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No
Research Institution Information:
University of Delaware
201 Composite Manufacturing Science Lab
Newark, DE 19716 3144
Contact Phone: (302) 831-8149
RI Type: Nonprofit college or university