Grant: Idea to Innovation

Polymer-matrix composite materials (PMCs) are characterised by high strength, high stiffness and low mass. These properties make PMCs ideal for airframe construction as mass reduction has a measurable impact on operating costs. Aerospace PMCs are fabricated materials based on carbon fibres: in lower-cost, out-of-autoclave processes these fibres are woven, braided or stitched into fabrics and infused with curable resins such as epoxy. PMCs have been used for making simple, thin, '2D' airframe components for decades. As further weight reductions are sought PMCs are increasingly considered for complex airframe parts. Advances in PMC and textile technologies are needed for reliable, efficient and economical production of PMC parts with complex 3D shapes, thick sections and high fibre content, to predictable performance specifications. The aim of this i2i proposal is to demonstrate the commercial viability of an innovative manufacturing technology for carbon fibre reinforcement preforms used in aerospace polymer composite parts. In the proposed programme we will demonstrate a pre-production manufacturing process and equipment for net-shape 3D preforms, that overcome major current challenges facing reinforcement production for PMC part manufacturing. We will produce demonstrator preforms using the manufacturing process and equipment. We will secure a partnership with an end-user in the aerospace industry, leading to a new venture to develop and manufacture 3D carbon fibre preforms and ultimately PMC parts to end-user specifications. The industry seeks new ways and methods for decreasing costs, increasing the array of feasible parts, and increasing potential applications of PMCs. The uOttawa Net-Shape 3D Preform technology enables this through improved fabrics, thereby reducing PMC manufacturing costs and providing aircraft manufacturers with increased design possibilities. The uOttawa technology addresses these challenges, offering great potential in moving 3D preform technology to a greater number of applications in aerospace and other markets.