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Hexcel Corp. (Stamford, Conn., U.S.) is strategically collaborating with A&P Technology (Cincinnati, Ohio, U.S.) to work with the AFRL-funded Modeling for Affordable, Sustainable Components (MASC) research program and Wichita State University’s National Institute for Aviation Research (NIAR, Kan., U.S.) to develop a methodology for certification of overbraided structures using Hexcel’s IM7 24K fiber and 1078-1 resin system

“Our collaboration with A&P Technology represents a significant step forward in delivering critical airworthy composite preforms at high rate,” says Lyndon Smith, president, Americas and global fibers, Hexcel. “By combining our advanced fiber and resin technology with A&P Technology’s overbraiding expertise, we’re enabling the next generation of high-performance military and commercial aircraft structures.”

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A&P Technology, a manufacturer of engineered braided reinforcements using its line of braiding machinery, has developed the capability to overbraid large-scale aircraft structures at high rate. Development of composite specifications, design data and a methodology for certification acceptable to the Federal Aviation Administration (FAA) will enable the adoption of this high-performance, low-cost, high-rate preform and part manufacturing by commercial airframe builders and will aid in its adoption into military platforms.

“Together, we are using feedback from specific aerospace primes to create preliminary design values for matrix systems, which will accelerate the process for full qualification and certification.”

Hawthorn Composites (Miamisburg, Ohio, U.S.) is currently producing inlet ducts for the Kratos XQ-58A Valkyrie using this overbraid and resin infused approach. Hawthorn has manufactured full-scale wings and fuselages for the same vehicle using similar approaches under the Design for Manufacture of Attritable Aircraft Primary Structure program (DMAAPS) program that culminated with a successful full-scale ground vehicle static test conducted by the AFRL. Independent analysis conducted by the AFRL concluded that use of braiding and overbraiding techniques on these types of parts would result in 57% cost savings when compared to hand applied prepreg and autoclave cure, and a 67% reduction in touch time.

“Net-shape braided preforms and overbraiding are both key technologies enabling the U.S. Department of Defense to realize their vision of affordable mass aircraft solutions,” notes Tom Margraf, CEO of Hawthorn Composites.

Overbraiding creates a controlled and predictable fiber change along the length of a part, including those with complex curvatures. Changing angles create mechanical property variation, but the controlled architecture allows for prediction of property change and creation of design envelopes.

The design of a composite combat drone inlet duct produced by NIAR, A&P Technology and Fiber Dynamics (Wichita, Kan., U.S.) will be used as the basis for the certification development. The complex curvature of the duct represents the types of aircraft structures that will require a path to FAA certification to take advantage of the high rate of manufacture benefits by overbraiding. A process is now in place that enables production of multiple duct preforms per shift, which opens a path to certification and adoption, according to officials from A&P Technology and NIAR.

“The overbraided serpentine inlet duct we developed under the MASC program is an excellent example of our partners’ capabilities and shows how modern braided composite technologies can advance aerospace innovation,” says Dr. Waruna Seneviratne, director of NIAR’s Advanced Technology Lab for Aerospace Systems (ATLAS). “Together, we are using feedback from specific aerospace primes to create preliminary design values for matrix systems, which will accelerate the process for full qualification and certification.”

“We’re excited to collaborate with Hexcel on this initiative,” says Andy Head, president of A&P Technology. “Our combined technologies offer a compelling solution for OEMs looking to quickly and consistently lay down fiber on complex load paths in complex geometries. This program will validate that the resulting structures are as easy to model and certify as incumbent, rate-limiting solutions.”