3D-woven composites find success in aerospace, space

Bally Ribbon Mills (BRM, Bally, Pa., U.S.) designs, develops and manufactures highly specialized engineered woven fabrics. BRM experts are on hand in to discuss the company’s 3D woven joints, thermal protection systems (TPS) and other 3D structures.

In partnership with NASA (Washington, D.C., U.S.) BRM recently developed a 3D orthogonally woven 3DMAT quartz material for the Orion Multi-Purpose Crew Vehicle’s (MPCV) compression pads. 3DMAT was named the 2023 NASA Government Invention of the Year.

BRM uses 3D continuous weaving to create new joint structures and improve existing joints. Delivering an optimal blend of strength, durability and structural integrity, BRM’s 3D woven joints are available in “Pi – π,” double “T,” “H” and other complex net shapes. According to the company, these joints reduce weight and cost without sacrificing integrity and performance. Because of the nature of the 3D weave, strength and support is translated in all three dimensions, thus enabling the join to reinforce the strength along the load paths of the substructures being joined together. These woven shapes can be tailored to suit the architecture of the structure itself, as well as the subcomponents being joined.

3D woven composites by BRM are said to be particularly successful in aviation heat shield applications such as TPS. These systems are mission-critical components, particularly in space exploration vehicles. The ability to vary yarn types, density, thickness and width, as well as resin type, enables BRM to create fully customizable TPS to fit each specific mission or application’s needs.

Along with TPS systems, 3D woven components also function well as engine parts in aircraft. Replacing traditional titanium engine components with 3D woven carbon fiber composites serves to reduce weight and therefore lifetime cost, all while meeting the rigorous demands of manufacturing and use.