In Situ Manufacturing System for Large Unitized Composite Space Structures

Abstract

Ares V dry structures are larger than any unitized composite space structures built to date. Conventional manufacturing methods do not apply to parts of this size and autoclaves simply do not exist, requiring an open trade space to develop applicable manufacturing methods. Northrop Grumman is developing an In-situ Manufacturing System (IsMS) to fabricate large unitized composite space structures. This system eliminates facility constraints due to moving a very large part from one processing station to another. Large composite structures are built in place (in-situ) by bringing the appropriate processing equipment and environment to the component. Reducing moves, minimizing required floor space and eliminating the need of an autoclave reduces the risks inherent in the scale up of traditional methods. The IsMS incorporates a flexible automated tape lamination head which can apply various widths and fiber/resin system tapes and a portable oven enclosure allowing part cure using out-of-autoclave techniques. To maximize the process efficiency, drill and non-destructive inspection processing heads are also integrated into the single footprint system.