Carbon Fiber PEKK Additive Manufacturing

The F-35 Lightning II Program continues to work toward successful full rate production. As part of that effort, the Program is seeking to leverage advanced technologies that will control or reduce costs to the platform while maintaining or improving overall weight and performance of the aircraft. Most F-35 Lightning II components were designed prior to additive manufacturing (AM) technologies being considered a viable method for low load, non-flight critical parts. Due to advancements made in AM processes and materials, traditional fabrication methods may no longer be the most cost effective. This Composites Manufacturing Technology Center (CMTC) project leveraged and built upon previous data to validate HexPEKK® material and demonstrated performance against F-35 Lightning II specifications for non-flight critical parts.

The benefit to production, which is based on work currently in progress, is estimated at total potential cost savings over $16.0M for the program. This project developed an alternative method to fabricate non-flight critical parts that will support F-35 Lightning II production.

Candidate parts developed and tested during this CMTC project are targeted to implement on aircraft in FY2025. Follow-on implementation efforts will consist of re-design and approval of additional parts utilizing the Design Guide and Qualification Guide deliverables.

*Prepared under ONR Contract N00014-21-D-7001 as part of the Navy ManTech Program.

*DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited. DCN# 2024-11-6-309; Approval Date: 11/14/2024