SBIR-STTR Award

The K&C team proposes to leverage a unique rotary lathe technology that can peel hardwoods into ultra-thin veneers. The strength, quality, and pliability of ultra-thin veneers will lead to stronger laminate composites and more stable forming of complex 3D parts of compound curvature, without sacrificing durability and radio frequency (RF) transparency, through innovative use of natural wood and adhesive polymer materials. The proposed ultra-thin veneers flex and drape like. The use of the ultra-thin veneers will produce laminates with: 1) Consistent quality, by confining production thickness to the growth-ring thickness of the tree; 2) Less statistical variation in material properties, with ample opportunity to select high-quality plies and filter out natural defects; 3) Higher strength based on historical study that showed thinner veneers made plywood panels stronger; 4) Greater dimensional stability, by conforming to shapes without inelastic mechanical deformation, chemical modification nor added moisture from soaking or steaming; and 5) Greater damage tolerance based on recent studies of ultra-thin-ply Fiber-Reinforced Polymer (FRP) composites.

Benefit:
The successful completion of the Phase I research will result in a natural composite material that meets all the Navy requirements listed in the SBIR solicitation and suitable for fabrication of 3D shapes with double complex curvatures. Material properties, longevity, and ability to fabricate curved parts will have been demonstrated. The K&C research will pave the way for demonstrating more complex shapes and larger sub-scale components. Development and characterization of the manufacturing process, mechanical, and structural properties will further advance the use of the proposed natural composite material into full-scale components for missile applications.

Keywords:
complex curvature, complex curvature, Missile, wood, Fairing, RF transparent, nose cone, laminate, Composite

In this SBIR Phase II effort, the K&C team proposes to build upon the success of the Phase I effort and continue to develop the performance and manufacturability of the previous natural wood composite (NWC) designs capable of meeting program needs for mechanical properties, radio frequency transparency, environmental durability, thermal resistance, manufacturability and process scalability. The team will: 1) finalize the NWC design, 2) optimize and enhance the manufacturing process capable of prototype part production, 3) evaluate material properties of finalized NWC material, 4) fabricate sub-scale or full-scale prototype parts, and 5) perform mechanical and durability tests on prototypes.

Benefit:
The successful completion of the Phase II research will result in a NWC material that meets all the Navy requirements listed in the SBIR solicitation and suitable for fabrication of production part prototypes. Material properties, longevity, and ability to fabricate prototype parts will have been demonstrated. The K&C research will pave the way for interfacing with production parts and assemblies. Development and characterization of the manufacturing process, mechanical, and structural properties will further advance the use of the proposed NWC material into full-scale production ready components for missile applications.

Keywords:
Missile, laminate, Natural, Fairing, wood, Composite, nose cone