SATPC0040423 Tab 04 4 SOW Rev_Redacted.pdf

STATEMENT OF WORK

1.0 Introduction/Background:

The STMD Continuous Manufacturing of Rollable And Deformable Elements for Space (COMRADES) project is exploring the development of a new roll-to-roll fabrication process of thermoplastic composites (TPC) parts using Continuous Compression Molding (CCM) to increase significantly the length of deployable composite structures such as booms, panels or curved shells. The use of new thin-ply thermoplastic composites enables very long deformable structures to be manufactured via CCM efficiently in a continuous manner via a roll-to-roll process instead of a piecewise manner via traditional CCM or by producing higher cost tooling/molds as long as the final parts themselves.

2.0 Scope of Work:

This SOW covers the design and fabrication of specific mold and tooling for a flat CCM machine to fabricate thin-wall corrugated panels designed by NASA with NASA provided thin-ply thermoplastic composite (TPC) prepreg material. It is a path finder effort that will perform fabrication sub-scale trials of the new roll-to-roll CCM process using a flat CCM machine available at the contractor facility. Similar corrugated panels have been manufactured before at NASA as shown in Figure 1 for reference.

Fig. 1 Previous thin-wall corrugated panel fabricated at NASA.

The carbon fiber/PEKK composite prepreg material is to be delivered by NASA to the contractor as a plain weave prepreg fabric in an uncured condition to serve as the raw material to create composite parts via CCM with NASA specified laminates.

The nominal shape of the desired corrugated panels is also to be delivered by NASA to the contractor via a 3D computer aided design (CAD) file. Figure 2 shows the approximate nominal cross-section shape of the desired corrugated panel to be fabricated via CCM.

Fig. 2. Approximate cross-section shape of the corrugated panel with overall size dimensions.

3.0 Objectives:

The contractor shall deliver the listed products in accordance to the specifications listed and under the tolerances outlined.

4.0 Description of the Work/Contractor Tasks:

The contractor shall fabricate and deliver for NASA the following thermoplastic composite products listed on Table 1. These products shall be produced with the specifications listed and under the tolerances referenced:

Table 1: Thin-ply thermoplastic composite products to be fabricated.

Shape Width (m) Length (m) Thickness

(mm) RC % Quantity

Development Flat Panel

(TCV)

0.6 (±0.010) 1 (±0.1) 0.4 (±0.05) 42 (±2) 1

Development Corrugated Panel

0.6 (±0.001) 0.75 (±0.1) 0.4 (±0.05) 42 (±4) 3

Final Corrugated Panel

0.6 (±0.0005) 7 (±0.001) 0.4 (±0.05) 42 (±2) 8

• Task 1.0 – Tool Fabrication The contractor shall design one tool for the Flat CCM, based on 3D files provided by NASA. This tool will create one unique corrugated panel part as shown in Fig. 2 that could be combined in the future to form a wider corrugated panel as shown in Fig. 3.

Fig. 3 The 0.6 m wide corrugated panels could be joined side by side to form wider corrugated panels.

Requirements Contractor shall design the CCM tool, pre-former, grippers/spacers, and a trim fixture.

Tool design shall include a scribe line for trim.

Contractor shall have a Critical Design Review (CDR) prior to fabrication that includes the NASA TPOC.

Contractor to fabricate all equipment and tooling needed following the CDR.

Task Deliverables Critical Design Review.

One CCM tool and required accessories.

• Task 2.0 – Deliverable Manufacturing The contractor shall use the tool from Task 1 to develop a setup card and fabricate corrugated panels to be validated by NASA.

Assumptions NASA supplies all composite prepreg material for deliverable panels, TCV panels, and setup card development of M30SC/PEKK composite prepreg at nominal 60 g/m2 areal density.

Contractor is not responsible for bonding panels.

A cross-section trim fixture can be used to hold parts rigid while cutting along scribe lines.

Panels can be rolled onto a spool to help with trim.

Requirements Run development corrugated and flat panels and TCV’s to build a CCM setup card and roll-to-roll CCM process.

Run 8 final corrugated panels, 7 m long and 0.6 m wide.

Trim width of panel to meet width tolerance of ±0.5 mm.

Perform visual inspection of the final panels and perform dimensional measurements.

Panels shall be individually rolled onto spools for easier transport and travel after

CCM consolidation.

Task Deliverables

► Deliver to NASA 8 final conugated panels 0.6 meters wide and 7 meters long.

• Development and final items shall include a test repo1i and ce1iificate of compliance.

• Monthly progress meetings with NASA are requested.

5.0 Deliverables and Period of Performance:

The contractor shall deliver the products listed in Section 4.0 no later than August 31th

2026.

Items shall be delivered to the following address:

NASA Langley Research Center Building 1238B, Room 127 Hampton,VA 23681-2199 Phone: 757-864-4034