Form 9.B Project Summary

Chron: 971872

Proposal Number: 05.01-2800

Project Title: Integration of Materials and Technologies into an Innovative,

Low-Cost, Composite, Spray-Up Toolings System (STS)

Technical Abstract (Limit 200 words)

The propesed innovative Spray-Up Tooling System incorporates low-cost foam, resin and metallic-arc sprays in the fabrication of dimensionally accurate, durable, composite patterns, molds and assembly fixtures used for rapid prototyping and low-cost manufacturing of composite parts and assemblies. The proposed Spray-Up Tooling System integrates several existing technologies to produce precision tooling using labor with less than "master" skill levels. The STS tooling concept also uses integrated engineering, drafting, and anufacturing

computer tools for design and fabrication, resulting in increased accuracy and repeatability unattainable in hand-fabricated patterns, molds, and fixtures. A thorough investigation of materials and processes will result in the selection of primary candidates for specific testing. The then best-tested processes and materials will be down-selected at the end of Phase I for completion and demonstration of a complet Spray-Up Tooling System in Phase II effort. Successful development of the proposed STS will represent significant improvements in composite tool economy, reductions in prototype design and fabrication lead times, precision fit of composite assemblies, and lower overall life-cycle costs of composite tooling for General Aviation (GA) parts and assemblies.

Potential Commercial Applications (Limit 200 words)

Completion of the Spray-Up Tooling System will result in immediate incorporation into the certified production process of the Global GT-3 Trainer Airplane and the Global QCS Propeller. Global Aircraft Corporation (GAC) also plans to utilize STS in tool fabrication and rapid prototyping of composite parts for GA aircraft as well as other commercial applications. The STS and services provided by Global Aircraft will benefit smaller composite production companies who are seeking improved component quality and ower unit costs. A Spray-Up Tooling System will make composite technology advances more readily available and affordable to General Aviation manufacturers and consumers. The low-cost aspects of the Spray-Up Tooling System will facilitate success for the commercialization endeavor.

Name and Address of Principal Investigator (Name,

Organization Name, Mail Address, City/State/Zip)

Michael Pastelak

Global Aircraft Corporation

P.O. Box 850

Starville , MS 39760

Name and Address of Offeror (Firm Name, Mail Address,


Michael R. Smith

Global Aircraft Corporation

P.O. Box 850

Starkville , MS 39760