ILC has an extensive materials development and test capability allowing us to prepare and evaluate prototype materials prior to a production run. Our in-house materials processing capabilities include: solution, transfer, and calender coating as well as film extrusion and laminating. We have developed coated and laminated materials using light nylon fabrics, polyesters, high modulus aramids such as Kevlar, and liquid crystal polymers including Vectran. Some of our analytical capabilities include infrared spectrophotometry, thermal analysis, gas chromatography, and microscopic FTIR. We also have a fully equipped chemical laboratory.
Some of the materials challenges we've solved for our customers are detailed below:
Inflatable Sunshield In Space (ISIS)
Problem:
Develop a Composite Laminate Rigidizable Laminated Structure for the ISIS Boom.
Desired Properties:
- High Strength Gas Retaining
- High Flexiblity for Efficient Stowage
- Capable of Being Rigidized in Space
- Two Year Shelf Life on All Materials
Solution:
Developed a Highly Latent, 250°F Cure Epoxy Prepreg System. In addition, Selected and Qualified a Structural Adhesive for Bonding Restraint and Bladder. Fabrication of Prototype at ILC Dover Boom Diameter: 5.125", Length: 18' 4"
Commercial Lightship Hull Material - Blockbuster Blimp
Problem:
Develop a Hull Material for Commercial Lightships That Exhibits:
- High Strength/Weight Ratio
- 5+ Years Service Life (UV)
- High Durability
- Translucency
- FAA Certification
- Flex/Crack Resistance
Solution:
Developed a Flexible Composite Construction Within a 6 Month Time Frame.
Utilizes: Polyester fabric for strength, coupled with multiple films for environmental resistance and stability
Mars Pathfinder Impact Attenuation
Problem:
Develop a Coated Fabric for the Impact Attenuation Bags for the Lander.
- Desired Features Include: Very High Specific Strength
- High Puncture Resistance
- Gas Retaining
- No Offgassing Under High Vacuum
- Excellent Flexibility @ Mars Ambient (-80 C)
Solution:
Developed a Coated Fabric Using Silicone Rubber And Vectran™ Liquid Crystal Fabric
Pioneered Vectran™ Fabric Utilization in Aerospace and Tendon Construction for Load Distribution in Inflatables
Pressure Retaining Bladder
Problem:
Develop an Enhanced Pressure Retaining Bladder Material for the Shuttle Space Suit.
- Desired Properties: High Strength
- Gas Retaining
- Thermally Sealable
- Withstand Repetitive Flexing Without Delamination of the Coating
- Resist Tear Propagation
Solution:
Developed and Qualified a Replacement Bladder Material. New Material Consists of a Thermoplastic Urethane Laminated to a Nylon Basecloth. Astronaut Kathryn C. Thornton, Hubble Repair Mission Specialist
Flexible Film For High Potency Pharmaceutical Intermediates
Problem:
Develop a Flexible Packaging Film for Packaging of High Potency, Pharmaceutical Intermediates.
- Desired Features Include: High Strength and Toughness
- Excellent Chemical Resistance
- Transparent
Solution:
Successfully developed "Armorflex" packaging film. Represents a "state of the art" technology in un-supported films. Flexible Film for High Potency Pharmaceutical Intermediates
