NASA 1996 SBIR Phase I

PROJECT TITLE : Low Cost RTM with Integral Energy Absorption For GA Composite Structures

TECHNICAL ABSTRACT (LIMIT 200 WORDS)

Stoddard-Hamilton Air, Inc.'s innovation is a Resin Transfer Molding process for making low cost monolithic General Aviation structures with integral energy absorption material. SHAI has market demand for this innovation because it can use low cost tools, materials and resin injection/infusion techniques for component fabrication that can meet FAA production certification requirements. SHAI's will partner with Impact Dynamics Inc. to design integral energy absorption that can be cocured in one fabrication step in order to minimize the parts count and thereby cost. The advantages over conventional secondary bonding of these materials are gained in labor time, quality, reliability and FAA certifiability. SHAI proposes developing a single sided vacuum bag RTM process using composite molds, silicon rubber arbors, low cost vinylester resins ($2.00/lb.) and vacuum assisted pressure pot injection. These cost a fraction of aerospace processes ($30 - $80/lb). that employ matched metal molds, and computer controlled injection systems. The RTM parts fabricated will be high quality dimensionally accurate and allow complex three dimensional curvature. SHAI will employ these cost advantages in its volume production line and in contract parts manufacturing. The low cost innovation meets the goals of the AGATE ID&M Workpackage and with NASA's mission goals of GA revitalization.

Stoddard-Hamilton plans to pursue four commercialization paths for this low cost fabrication technology:

1. To incorporate this RTM process into its Glastar volume production line.
2. To use it to manufacture FAA Part 23 certifiable cowlings and instrument panels for an established GA airframe retrofitter, Mod Works, who will obtain a STC for these.
3. SHAI will pursue similar sub-contract primary airframe parts manufacturing for other GA manufacturers such as Cirrus Design.
4. SHAI's business plan to seek FAR Part 23 certification for the Glastar remains alive, this process will directly provide lower cost to the customers.

Robert M. Gavinsky
Stoddard-Hamilton Aircraft, Inc.
18701, 58th Ave, N.E.,
Arlington, WA 98223

Robert M. Gavinsky
Stoddard-Hamilton Aircraft, Inc.
18701, 58th Ave, N.E.,
Arlington, WA 98223