Development of New Repair Technologies for Out-of Autoclave Aircraft Composite Components

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Today a significant amount of primary structures of civil aircrafts are made of composite materials. This type of structures is mostly manufactured by autoclave processing. However, the need to increase production rate and to lower manufacturing cost have led to the development of new manufacturing techniques that do not require an autoclave. New out-of-autoclave (OOA) prepregs have been formulated to allow part manufacturing using vacuum-bag-only (VBO) under atmospheric pressure. These changes in the design and manufacture of commercial aircraft require new design and analysis tools, new methods of inspection and maintenance, and new repair methodology. Engineers responsible for damage assessment and repair designs currently do not have sufficient reliable analysis methodology or practical tools to design high confidence repairs.