MCAST SBORAEK: Transforming Aerospace Repairs With Cutting-Edge 3D-Printed Kevlar Shields
At the heart of Malta’s innovative aerospace advancements, the SBORAEK project (Smart Ballistic Optimisation for Repairing Aerospace Exostructures using 3D-printed Kevlar) is making waves with its groundbreaking approach to repair techniques.
Spearheaded by the esteemed Dr. Leonardo Barilaro, Senior Lecturer in Aerospace Engineering at the Malta College of Arts, Science and Technology (MCAST), this initiative is proudly supported by the Malta Council for Science & Technology through the FUSION—Technology Development Programme LITE.
Just as Börek—a beloved Turkish pastry known for its delicate layers of yufka dough—serves as a culinary inspiration, the SBORAEK project draws from this concept to craft layered, high-performance repair solutions. The project leverages a state-of-the-art 3D printing technique to create robust Kevlar® and carbon fibre shields, setting new standards in aerospace repair.
Ensuring the safety of aircraft and spacecraft is paramount, yet traditional repair methods can be both costly and time-consuming, especially when addressing damage from micrometeoroids or space debris. SBORAEK offers a fresh perspective with its innovative 3D-printed patches, designed to deliver precision repairs swiftly and efficiently.
Supported by MCAST’s Institute of Engineering and Transport (IET), SBORAEK is poised to revolutionise the repair process. By enabling on-site repairs, the project aims to reduce both downtime and costs, while offering superior customisation that minimises material waste and weight. Its potential extends beyond conventional aviation, promising valuable applications for the International Space Station and future spacecraft missions.
SBORAEK focuses on three key goals:
- Optimising the Design: Developing 3D-printed shields with enhanced ballistic performance.
- Creating Custom Patches: Using continuous aramid fibres and other materials for bespoke repair solutions.
- Reducing MRO Time: Streamlining the repair process to cut maintenance, repair, and overhaul times.
The project has been showcased on international stages, including the International Astronautical Congress 2023 in Baku, Azerbaijan, the AIDAA 2023 conference in Padua, Italy and at Khalifa University in Abu Dhabi, UAE.
Notably, SBORAEK culminated in a series of rigorous tests conducted in collaboration with Thiot Ingenierie (France). Their Hypervelocity Impact facility, featuring a Light-Gas Gun, was used to assess the ballistic performance of the 3D-printed Kevlar shields, ensuring they meet the high standards required for aerospace applications.
The success of SBORAEK is a testament to the collaborative efforts of MCAST, CISAS of the University of Padova (Italy) and Skyup Academy (Italy). This synergy of aerospace engineering, materials science and 3D printing technology marks a significant leap forward in aerospace repair capabilities.
For those inspired by this pioneering work and interested in exploring aviation studies, MCAST’s Institute of Engineering and Transport (IET) offers a range of educational programmes.
Prospective students can download the MCAST prospectus and apply online via the College website.
To learn more about SBORAEK, visit their website.