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The AERoBOND and AERoBOND+ technologies are composite resin materials design innovations that enable new methods for composites joining and manufacturing. The resins are formulated with carefully selected off-set stoichiometries to delay/control the cure such that initial curing of individual components can be followed separately by joining/curing of components together. The ability to delay and control the co-cure joining step provides ease of manufacturing of multi-part composite structures, without compromising joint integrity. There are significant cost savings associated with eliminating fasteners and joint surface preparation steps. To date, the focus of the NASA development effort has been on novel epoxy-based prepreg formulations though other types of thermosets could be considered as well. The AERoBOND+ innovation provides an added adhesive layer to the AERoBOND joint design to improve the ability to join composite surfaces when these surfaces are less tightly matched. Conventional adhesives, e.g., film, paste, etc., are employed. By including an adhesive between the offset stoichiometric prepreg plies, the adhesive can fill the gaps between the bonding surfaces while maintaining reflowable AERoBOND layer interfaces. Since all interfaces are reflowable, they are much more tolerant of surface contamination, thereby mitigating a primary challenge for conventional adhesive bonding.

The SSS-Joint is an interlocking joint system for joining structure components such as struts, flat truss frames, and volumetric truss bays together to build bigger and more complex structure systems. The SSS-Joint interface can be applied to various connection scenarios commonly found in truss structure assembly, including but not limited to strut-to-strut connections, strut-to-node connections, and half-node-to-half-node connections. By incorporating half-node joints, the number of standalone components can be reduced by over 52%, and assembly steps can be decreased by over 65% compared to traditional truss tessellations without half-nodes. In the current design, a single screwdriver can assemble all connections. The interlocking geometry of the SSS-joint features built-in guiding elements to aid the alignment process. Once in place, the screwdriver can rotate and engage with the spring-loaded captive lock-screw on the joint. The screwdriver tip does not need to be perfectly aligned, as the spring-loaded lock-screw will automatically pop into place within half a rotation after contact. This design dramatically reduces the complexity of the assembly process and eliminates the need for loose fasteners or specialized tools. The SSS-joint offers a robust, lightweight, and scalable solution for modular structural assembly in space and terrestrial applications alike. The SSS-Joint has reached Technology Readiness Level (TRL) 5 (validated in a relevant environment) and is available for patent licensing.