SBORAEK (Smart Ballistic Optimisation for Repairing of Aerospace Exostructures Using 3D Printed Kevlar) is expected to transform aerospace structure repair procedures. The project, led by Dr. Leonardo Barilaro, Senior Lecturer in Aerospace Engineering at the Malta College of Arts, Science, and Technology (MCAST), is funded by the Malta Council for Science and Technology’s FUSION—Technology Development Programme LITE.
The project’s acronym, based on Börek, a savoury traditional Turkish pastry made with thin, flaky yufka dough (likely from the Turkic word “bur”, meaning “to twist”), reflects the clever methodology used to create layered structures. The SBORAEK shields are made with an innovative 3D printing method that uses continuous aramid fibre materials such as Kevlar® and carbon fibre.
3D Printed Kevlar to repair aerospace structures
Maintaining the structural integrity of aircraft and spacecraft is critical to safety. Current repair techniques can be time-consuming and costly, particularly for damage caused by high-energy impacts from micrometeoroids or space debris. SBORAEK proposes a novel solution for creating custom repair patches with 3D printing technology.
This project, which is also supported by MCAST’s Institute of Engineering and Transport (IET), has the potential to reduce downtime and repair costs through on-site repairs, achieve superior customisation that reduces wasted materials and weight, improve overall repairability, and find applications beyond traditional aviation in modules of the International Space Station and future spacecraft.
SBORAEK’s three main goals are to develop a method to optimise the design of 3D-printed shields for superior ballistic performance, to create custom repair patches using 3D-printed continuous aramid fibres combined with other materials for enhanced functionality, and to reduce MRO (Maintenance, Repair, and Overhaul) time by streamlining the repair process.
The project was showcased at several international events, including the International Astronautical Congress 2023 (Baku, Azerbaijan), the AIDAA 2023 conference (Padua, Italy), and Khalifa University (Abu Dhabi, UAE).
SBORAEK concluded a series of tests in collaboration with Thiot Ingenierie (France); their Hypervelocity Impact facility includes a Light-Gas Gun, which was used to evaluate the ballistic performance of 3D printed kevlar shields intended for aerospace applications.
SBORAEK’s success is dependent on collaboration among MCAST, CISAS at the University of Padova (Italy), and Skyup Academy (Italy). This combined knowledge of aerospace engineering, materials science, innovative simulations, and 3D printing technology paves the way for significant advancements in aerospace repair.
The MCAST Institute of Engineering and Transport (IET) provides a diverse range of aviation education programs. Applicants interested in beginning or advancing their studies in this field can download the MCAST prospectus and apply online through the College’s website.
