Novel fabrication techniques for low-mass composite structures in silicon particle detectors

The structural design of silicon-based particle detectors is governed by competing demands of reducing mass while maximizing stability and accuracy. These demands can only be met by fiber reinforced composite laminates (CFRP). As detecting sensors and electronics become lower mass, the motivation to reduce structure as a proportion of overall mass pushes modern detector structures to the lower limits of composite ply thickness, while demanding maximum stiffness. However, classical approaches to composite laminate design require symmetric laminates and flat structures, in order to minimize warping during fabrication. This constraint of symmetry in laminate design, and a “flat plate” approach to fabrication, results in more massive structures. This study presents an approach to fabricating stable and accurate, geometrically complex composite structures by bonding warped, asymmetric, but ultra-thin component laminates together in an accurate tool, achieving final overall precision normally associated with planar structures. This technique has been used to fabricate a prototype “I-beam” that supports two layers of detecting elements, while being up to 20 times stiffer and up to 30% lower mass than comparable, independent planar structures (typically known as “staves”).