An Evaluation of Composite Primary Structure for Habitat Modules

Boeing studied the use of composite structures in deep space habitats. Compared to metallic modules, composite structures offer increased strength and stiffness with reduced mass. The study evaluated the design considerations and the mass benefits of an all composite primary structure. The composite module design included a continuous pressure shell, composite longerons, and circumferential ring frames. The composite material selected was a high strength carbon fiber and epoxy slit tape prepreg. The manufacturing involved automated fiber placement and utilizing existing facilities and autoclaves. Analysis showed a 33% reduction in primary structure mass and an overall net reduction of nearly 1900 kg compared to metallic modules. The composite module demonstrated improved mass efficiency and opens new possibilities for mission performance in deep space exploration.