SBIR-STTR Award

Program Summary: ElectraFly ORB Personal Transport Aircraft - CBAM 3D Parts Overview: New materials and advanced manufacturing processes will facilitate the production of ORB aircraft through lower weights, lower cost, improved processes, and greater strength. ElectraFly is developing a <55lb prototype test vehicle using 3D Carbon Based Additive Manufacturing (CBAM) for flight testing, before seeking FAA authority to flight test the larger aircraft, which will carry a person. Phase I Technical : Build a <55lb prototype for compliance with FAA 107, using carbon fiber to reduce the aircraft weight and utilizing CBAM for small parts and structures. Technical Merit: Flight testing under FAA 107 will provide data to support the ElectraFly full-size vehicle and for other ORB aircraft to use 3D CBAM to reduce aircraft weight. The team will consist of the following ElectraFly as the small business, Weber State University as the research institution, Utah Advanced Materials and Manufacturing Initiative (UAMMI) as the industry partner, Impossible Objects as the corporate partner, and America Makes as the DoD Institute.

Composites manufacturing using autoclave cured pre-preg materials is expensive, often size limited, labor intensive, and has slow cycle times limiting production. The AFRL reported the need for improved composite research and demonstrations related to the emerging Advanced Air Mobility market. This project will use novel, out of autoclave composite manufacturing methods including composites based additive manufacturing (CBAM), carbon fiber resin infusion, and 3D printed tooling to fabricate a sub 55 lb. VTOL aircraft. This work will build on an STTR phase I, optimizing the processes for VTOL fabrication.