Flight Vehicle Composite Structures

TLDR

Composite technology transition required air‑framers to adopt new design and manufacturing methods that produce structures with properties measured after fabrication rather than relying on bulk material properties. These efforts produced unitized composite assemblies with complex shapes and fewer parts, achieving performance gains that enable unprecedented exploration of future advanced aircraft.

Abstract

To overcome obstacles for composites technology transition, air-framers embraced changes in design and manufacturing methods to produce structures from various material forms for which mechanical properties are ascertained after fabrication, rather than assembly of materials for which these properties are inherent to their bulk state. Changes in manufacturing processes were necessary to fully realize the promised composites performance benefits. New analysis and design methods were necessary to assure mechanical performance of assembled structures. These efforts have produced unitized composite structure assemblies formed to complex shapes, with substantially reduced part counts. Although the structural performance gains were the original goal, it is the outcome of the design and manufacturing efforts that will enable unprecedented exploration of future advanced aircraft.