The Air Force Research Laboratory (AFRL) successfully executed several phases of a Small Business Innovation Research (SBIR) contract to develop an advanced multi-axis braiding/filament winding work cell. The technology work cell has proven its ability to cut costs and improve the efficiency of manufacturing processes that scientists use to enhance the durability and safety aspects of critical, primary, load-bearing jet engine structures.

AFRL managed the effort, and A&P Technology (Cincinnati, OH) executed it. Scientists use the work cell, known as the Mantis, in the development of many applications, because hybrid composites composed of braid and filament winding have significantly higher resistance to buckling and flange bending than do conventional fabric composites. The team developed an affordable process based on combining braid and filament winding capabilities in a single work cell. Scientists will use the successful technology development to provide stronger military and commercial products. The technology has already strengthened the fabrication of the composite exhaust shroud for the General Electric F110 engine.

How it Works

Prior to the program’s initiation, scientists completed braiding and filament winding processes on separate machines, which required removal from one machine to the next and shipment to separate facilities. This caused extended processing time and increased costs related to hybrid composite manufacturing. The team focused on the improvement of manufacturing process efficiency by combining both the braiding and filament winding processes and the machines used for the two processes. The consolidation of the two processes into a single hybrid machine allows for significant process improvements and cost savings.

This successful testing led the team to explore further development efforts and resulted in the Mantis work cell, which is an integrated, multi-axis, hybrid braiding machine that provides a mature, repeatable manufacturing process.

Where it Stands

The Mantis work cell is an ideal technology for the production of nonlinear parts such as ducts and fuselage ribs. The technology also has potential in the commercial manufacturing of automotive parts, medical prosthetics, sports equipment such as hockey sticks and tennis rackets, and recreation equipment such as bicycle components.

More Information

For more information on A&P Technology’s Mantis work cell, click here. (Source: West Virginia High Technology Consortium Foundation)