Bindatex Advanced Materials Cutting collaborated with the National Composites Centre (NCC). The innovative project involves Thales Alenia Space and SHD Composites Materials. This project demonstrated the feasibility of the UK manufacturing supply chain in producing all-composite linerless (Type-V) tanks for space applications. These tanks, aimed at launch vehicles and satellite propellant systems, offer approximately 30% weight savings over traditional metal tanks. A key factor in the project’s success was Bindatex’s expertise and knowledge of slitting to tight tolerances. These capabilities are crucial for processing UD carbon fibre materials. This case study underscores Bindatex’s vital role and expertise in the precision slitting of thermoset composite prepreg tapes, essential for manufacturing Type V hydrogen storage tanks.
The Challenge
The SpaceTank project aimed to develop the UK’s capabilities in manufacturing and inspecting cryogenic pressure vessels. Such vessels are key to the space industry’s quest for cost efficiency. The weight reduction achieved in these tanks directly translates into cost savings. This benefit is vital for positioning the NCC as a leader in lightweight composite solutions for space propulsion. Additionally, the project highlights Bindatex’s expertise in the precision slitting of UD composite tapes.
Project Background
As the space industry increasingly adopts composite materials, the SpaceTank project focused on developing innovative solutions for storing cryogenic propellants such as liquid hydrogen and liquid oxygen. This initiative places the UK among global leaders in composite tank technology.
Innovation and Manufacturing Process
The NCC’s SpaceTank demonstrator is 750mm long, 450mm diameter tank and a 96-litre capacity. Construction utilised advanced composite design and manufacturing techniques. Weighing only 8kg, the tank’s carbon composite body was engineered using high-modulus carbon fibres. This approach optimises for weight and pressure resistance. A key feature of this innovative tank was the co-bonding of metal fluid valve ports during the manufacturing process. This eliminates the need for secondary assembly and enhances structural integrity.
Central to the tank’s construction was the use of Automated Fibre Placement (AFP) technology. This cutting-edge manufacturing technology utilises the automated, precise placement of composite fibres, ensuring uniform material distribution and optimal structural performance. The NCC employed AFP to lay up the precision-slit carbon prepreg tapes onto a specially designed, water-soluble core. This approach facilitated the creation of complex shapes and precise wall thicknesses necessary for the tank’s performance requirements.
Key Contribution by Bindatex
Bindatex played a pivotal role by providing expert precision slitting services for the MTC510 epoxy carbon prepreg, supplied by SHD Composites. Bindatex meticulously slit 22,000 meters of prepreg material within tight tolerances to 6.35mm width, a critical specification for the AFP process. Bindatex’s proprietary technology can format thermoset prepregs with high resin content or that are particularly tacky, ensuring consistent and high-quality slitting. This capability was crucial for maintaining the integrity and performance of the composite tapes during the AFP process.
Bindatex Advanced Materials Cutting for
Automated Fibre Placement (AFP) and Filament Winding
The high-quality slit tapes were then used by the NCC in the AFP process, where they were accurately placed onto the core tooling using a combination of helical and hoop-winding techniques. This meticulous process ensured the precise alignment and quality of the composite layers, crucial for achieving the desired mechanical properties and structural integrity of the hydrogen storage tank.
Due to Bindatex’s unparalleled expertise in precision slitting, we have been involved in the slitting of developmental UD prepreg thermoset tapes for numerous Type V hydrogen storage tank projects. Our work extends beyond the space industry, contributing to the future of greener commercial aircraft. By enabling the production of lighter, more efficient tanks, Bindatex supports the advancement of sustainable aviation technologies, aiming to reduce the carbon footprint of next-generation aircraft.
Overcoming Challenges
The project faced several challenges, particularly in developing a suitable tooling technique for the linerless tank. But also the precision slitting and spooling of a prepreg UD which had a high tack level requiring the unique technology and process that Bindatex has developed to enable these materials to be precision slit into AFP tapes.
The NCC collaborated with AeroConsultants to develop a water-soluble core material solution, which was essential for the complex manufacturing process. This innovative approach allowed for successful autoclave curing and easy removal of the core material post-manufacturing, leaving behind a fully formed composite structure.
Impact and Future Prospects
The successful completion of the SpaceTank project not only demonstrates the potential of composite materials in space applications but also lays the groundwork for future advancements in propellant tank technology. This achievement positions the NCC as a key player in the global space economy and showcases the UK’s growing expertise in composite technologies.
Conclusion
Bindatex’s precision slitting expertise was crucial to the success of the SpaceTank project, underscoring the importance of high-quality composite formatting in advanced aerospace applications. The seamless collaboration between Bindatex, the NCC and other industry partners highlights the UK’s capability in pioneering innovative composite solutions, setting the stage for future breakthroughs in space exploration.
This case study illustrates Bindatex’s indispensable role in advancing composite space tank technology, emphasising our unmatched precision slitting services for thermoset composite prepreg tapes. Our involvement in various developmental projects for the space industry and greener commercial aircraft demonstrates our critical role in shaping the future of aerospace technology by utilising the knowledge and expertise we have developed in slitting thermoset UD prepreg tapes.
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