Investigation, manufacture, and testing of damage-resistant airframe structures using low-cost carbon fibre composite materials and manufacturing technology

Abstract

A BAE systems/UK Government funded project, Flaviir, is investigating the design and manufacture of low-cost and damage-resistant carbon fibre composite airframe structure for large-scale unmanned aircraft vehicles (UAVs). The article discusses requirements and design concepts for low-cost wing structure. Techniques for manufacturing cost reduction and damage resistance enhancement are investigated through the design and test of spar to skin joints. The use of vacuum infusion processing with slotted-type joints and stitching of the detail parts by tufting were demonstrated to greatly increase the strength of spar to skin joints and to reduce the manufacturing cost. The results will be used for the design and manufacture of a large wing box demonstrator test structure, to be manufactured in 2009.