Automated Manufacture of Composite Aerospace Components at the UQ Centre for Hypersonics

Filament winding is an automated process in which a component is manufactured by winding a continuous fibre bundle impregnated with resin onto a mandrel in a programmed pattern. Filament wound parts are lightweight, low cost, consistently high quality and have exceptional strength and resistance to chemical and environmental degradation. This paper outlines the development of a computer-controlled composite manufacturing capability at the University of Queensland. Applications have included the manufacture of high-strength lightweight rocket motor and ramjet casings and nozzles. A filament-wound nosecone for a hypersonic engine flight test is being developed and technology is being extended to applications outside aerospace, such as mining and civil infrastructure. Many opportunities exist to further expand the range of applications of this technology, displacing metals and hand-laid-up composites; and to extend the technology itself by embedding electrical and optical conductors, sensors and actuators.