Craig Simpson

LOW COST MANUFACTURING METHOD FOR A GENERAL AVIATION AIRCRAFT FUSELAGE

This paper presents manufacturing methods and the process used to fabricate a low-cost, one-piece, integrally stiffened closed-shape co-cured composite small aircraft fuselage. The use of aerospace carbon- fiber/epoxy prepreg material has typically been too expensive for small aircraft structures. However, if fiber and resin are procured in low cost forms and combined in-process in the aircraft factory, then carbon fiber composite fuselages can be economically produced. Of primary importance is the controlled spreading of multiple fiber bundles to achieve a fiber bandwidth compatible with the creation of lightweight thin-skinned fuselages. In-process impregnation of the spread fiber bundles assures the integrity of the resulting composite structure and appropriate resin properties (in conjunction with correct cure processing). Computer controlled machine placement of the spread fibers assures correct fiber placement and orientation, resulting in the necessary strength. Inspection and structural testing of demonstration fuselages has verified that results obtained are consistent with expectations of the manufacturing methods used.