DEVELOPMENT OF A LOW-COST UAV FUSELAGE USING VARTM TECHNOLOGY

A low-cost center fuselage component for the Bell Helicopter Eagle Eye VTOL UAV has been designed using vacuum-assisted resin transfer molding (VARTM) fabrication technology. This component forms the structural backbone of this small tiltrotor aircraft and is also the primary fuel tank. A configuration trade study was conducted in which a relatively low-risk, low-integration concept was selected. The chosen configuration facilitated an assembly methodology using paste adhesive in all primary structural joints. Paste adhesive was chosen due to its workability and good performance in joints with gap variation. The paste adhesive detoleranced these joints and significantly reduced time consuming shimming operations. Fiber preform and resin selection were optimized for each part based on aircraft requirements and producibility constraints. Cost savings in this fuselage component are expected due to low-cost materials, low-cost layup, the inherent labor and tooling advantages of the VARTM process, and the aggressive assembly technique using relatively thick paste bonds for low-cost assembly. Manufacturing process development and risk reduction activities are described which validate the design.