Cobham developed and manufactured lightweight carbon fibre reinforced polymer matrix composite test components for the SAGE 4 Geared Turbofan demonstrator. The components were manufactured from suitable high temperature resistant thermoset resin which is capable of a continuous service temperature of 350°C. Initial working sessions were held to review the candidate components and to develop the draft technical requirement specifications. The composites manufacturing process selection were dependent upon the components to be manufactured. A study was carried out by Cobham to identify the most cost effective manufacturing route which achieves the required performance requirements for the selected components.

Development of the selected manufacturing process was conducted in collaboration with MTU so that key design-for-manufacturing requirements were captured. Demonstrator components were manufactured in accordance with MTU specifications and drawings. Material characterisation data was generated for unaged and thermally aged test coupons in order to validate the composite designs.