Challenges of aerospace structural part geometries for high-rate compression molding

Abstract

Thermoset matrices continuous carbon fiber composites show opportunities for high-rate production of aerospace small structural parts when processed in compression molding. Previous studies have presented the material development and automated process development for press forming of carbon fiber composites. Takt times under 30 minutes were demonstrated for primary and secondary structures. This was achieved by building a flat blank, which was then formed into final shape and cured without pre-forming step. A set of generic parts and associated steel tooling were generated. They include a range of geometries which present challenges for sub-30 minutes forming of a flat blank. The parts manufactured achieved aerospace structural performance. The paper presents how some of the main challenges were overcome, through both process and material development. The parts were designed by Boeing; pressed in Solvay's research and innovation facilities in Heanor, UK; and analyzed at Solvay research center in Anaheim, CA and at Boeing Saint Louis, MO USA.