An overview on Smart Ballistic Optimization for Repairing of Aerospace Exostructures using 3D printed Kevlar

Impact resistance, mass and quality-controlled manufacturing methods are key considerations for the selection of materials used in aerospace. Continuous Aramid Fibers (like Kevlar®) are widely used for reinforcement of military and civilian armour systems due to their excellent impact resistance and high strength-to-weight ratio properties. In recent years advancements in the aerospace sector revealed the need for improved repair strategies, following a high-energy impact, such as a bullet or a space debris collision. Additive manufacturing represents a promising field of research allowing for great flexibility in the design of multilayer protection shields and aerospace structures. This paper presents the roadmap to develop ballistic optimized 3D printed continuous fiber-based shields for aerospace high-energy impact applications. One of the core novelties is the multi-objective optimization procedure applied in the design of the experimental samples, which are evaluated through simulations and laboratory tests. The advantage of this process will be its implementation time frame when compared with traditional methods and the high level of customization possible for specific cases. The described project will represent a paradigm shift for repairing procedures applied to manned modules in space and for new and more efficient small satellite shields.