Additive Manufacturing Low Cost Carbon Fiber Composite Lattice Structures for Uncrewed Aircrafts

P. Poddar
PRISAM LLC, New York, United States

Keywords: Additive Manufacturing, Carbon Fiber Composites, Lattice Structures

PRISAM's technology is centered around their proprietary 3D printing process known as Axial Lattice Extrusion (ALE). This innovative technology enables the production of large-scale lattice structures, which offer exceptional strength and stiffness. The unique feature of ALE is its ability to align chopped carbon fibers in lattice beams, resulting in significantly improved structural strength and stiffness. Compared to traditional Fused Filament Fabrication (FFF) 3D printing, ALE boasts impressive speed, with a six-fold increase in printing velocity at Technology Readiness Level (TRL) 5. The technology shows the potential to reach TRL 8 by 2025, indicating production-level quality suitable for internal structure fabrication of unmanned aerial vehicles (UAVs) and CubeSats. One of PRISAM's significant strengths is its ability to produce lightweight lattice structures quickly and cost-effectively. These lattice structures have applications in various fields, including defense and aerospace. By integrating these structures into airframes and other components, PRISAM aims to enhance performance, reduce waste, and increase the competitiveness of products, both in the defense and commercial sectors.