Foster-Miller has developed a proprietary product and process for ultrasonic energy input during filament winding, and fiber- and tape-placement operations. This product provides on-the-fly consolidation, staging or curing of prepreg tape during fabrication, and eliminates the large number of interim debulking steps necessary to fabricate thick composite parts. This process will have a big impact on manufacturing cost, enabling new composite applications previously prohibited by high cost.

UTL™ equipment was designed and fabricated under Navy programs from 1997-2001. Teamed with Bell Helicopter and ATK, the process was demonstrated on a V-22 conversion spindle.  A series of V-22 panels fabricated using UTL™ showed equivalent properties to those made with standard vacuum bag debulking. A V-22 full-scale demonstration spindle fabricated for the program was evaluated. Using x-ray, C-scan, and void fraction Foster-Miller’s part was better quality than any manufactured spindles to date, including having no fiber waviness. The part fabrication required only one vacuum debulk step versus the standard six steps normally required; translating to a reduction in process time of  about 30 percent - a significant savings.  Following this success, a prototype commercial UTL™ head was designed, built and demonstrated.

UTL™ has also been developed for aircraft repair, fuel tanks for NASA’s RLV, and superconducting magnets. Foster-Miller expects to team with aerospace contractors for application specific manufacturing using UTL™. Foster-Miler will also facilitate installation of UTL™ equipment aerospace manufacturing facilities to enable lower cost fabrication of large structures.

Return to Advanced Materials

Printable Version