TOOLING DESIGN METHODS AND APPARATUS

Abstract

A tooling design that allows structures or components to be produced in a "one shot" process where secondary processes are limited or reduced to a minimum and where automated processes can be utilised so as to reduce the inaccuracies associated with manual production and in turn reduce the cost of said production. The tool consist of two sections which contain buttresses (9) and flanges (14), where the buttresses fit within the flanges. This design produces a structure and or component with two internal superstructures that are perpendicular to each other and forms a superstructure that can run the whole length of the final structure. Secondary processes can be applied if the structure is modified to act as a mould. The finished structure or component can be joined, if required to other completed structures or components thus increasing the size beyond that of the initial structure, whether it is a wind turbine blade or other large structures.

Description

1 / 45 “METHODS AND APPARATUS FOR TOOLING DESIGN”

[001] This patent application relates to the design of tools for the production of any large structure or component; for clarity, the terms “structures” and “components” are used. Structures, as defined in this patent, are large structures such as caissons, wind turbine blades, aircraft fuselages and wings, complete car bodies and other motor vehicles.

[002] Components are defined as components for automobiles, aircraft, trains, but are not limited to these.

[003] In addition, structures such as nacelles, nose cones for trains and aircraft, etc., as well as residential, commercial and industrial buildings of various types, such as factories, dams, silos and the like, while the components are generally defined as parts for vehicles, airplanes, trains, etc., but not limited to that, where these structures and components can be interconnected in sections (if necessary).

[004] Substructures are the internal structure of individual tools, known as buttresses / flanges in this patent, and are defined as structures within the tool or within the final component and / or final structure, such that the final component and / or structure produced from the tool has the structural integrity necessary for the specific final application. When the internal substructures of the tool that form the final component or structure are interconnected, they form an internal superstructure or “cross-section” for the final component or structure. This internal superstructure can be interconnected with the internal superstructure of an adjacent structure and / or component, as shown in this patent.

[005] Note also that I mention internal flanges and internal buttresses. Internal flanges are the section of the tool's internal structure where the buttresses fit into the flanges of the tool's internal structure, and also the horizontal and / or vertical internal structure of each tool section. The horizontal structure is connected to the external section of the respective tool. Petition 870250102381, dated 07 / 11 / 2025, page 9 / 69 2 / 45 while the buttress is connected to the horizontal structure, where the buttress is at a right angle to the horizontal buttress. Note that the flanges are also connected in a way that is and to the horizontal buttress, with one flange able to move towards the opposite flange, so as to compress the buttress that will enter and fit into the flanges of the incoming tool. (I also use the terms horizontal and vertical to indicate the orientations of the internal structures in the drawings). There is a buttress in each section of the tool and two

[006] flanges in each section of the tool, unless otherwise indicated below. The buttresses, horizontal buttresses and female flanges are part of each individual section of the tool that join together to form the final structure and / or component.

[007] Note that the final structure or component formed by the tool does not have flanges, only butts. The flanges are associated only with each section of the tool to form the internal structures or butts.

[008] It should also be noted that, for some applications, such as aircraft fuselages, at least one of the “vertical” buttresses would not be necessary, otherwise there would be a vertical structure running the entire length of the aircraft cabin, the horizontal buttress (forming the floor) would still be necessary along with the “lower” vertical buttress; for both sets of tools that form the final structure, in this case the fuselages of an aircraft, all structural integrity will be designed within the final structure and the tooling will take structural requirements into account.

[009] With respect to the required shapes of the final structure, whether conical, cubic, spherical or other, the tool will be designed for such structures and all structures, as described on page 1 / 16 and page 2 / 16 and corresponding pages, as described in this patent, which describes the tool, the tool will also be shaped to accommodate the above structures, both internally and externally (the outer surface, as seen Petition 870250102381, dated 07 / 11 / 2025, page 10 / 69 3 / 45 on page 12 / 16, Fig. 15, for example) of the aforementioned structures.

[010] In addition to the above, the final structure or component produced by the tool can also be used as a mold. An example of this use is the production of caissons, large structures produced predominantly from concrete and steel inserts that act as reinforcements for the concrete. These structures are typically extremely large, expensive to build, and time-consuming to produce, sometimes taking many years if it is a large reclamation project (e.g., land reclamation or sea reclamation), where hundreds, if not thousands, of these caissons may be needed; they are generally used to build structures on the sea surface, launching the caisson onto the seabed, thus acting (the caissons) as foundations for building structures.Therefore, the issues involved in constructing and moving these gigantic structures, some with 10 stories or more, represent a monumental task of engineering, design, and, of course, implementation. The tool design in this patent can produce the final structure that will act as a mold with minor modifications to the tools, making it possible to create these caissons in weeks instead of months and years, at a considerably lower cost. Furthermore, due to the lightness of the mold produced from carbon fiber, they can be transported by air or produced on the dock and taken to sea and placed on site; the concrete can then be poured into the mold. Note that the concrete reinforcements, as seen in this patent, are made using solid carbon fiber posts / tubes, but are not limited to this.To overcome the problems of concrete spillage when poured into the offshore mold, a fabric collar is placed around the outer surface of the mold neck. This collar is tight enough to ensure that no concrete can overflow into the sea. The surface of the collar floats on the sea surface by pontoons high enough to ensure that the concrete can be poured into the mold without spillage. See page [page number]. Petition 870250102381, dated 07 / 11 / 2025, page 11 / 69 4 / 45 Figure 5, No. 42, showing a thick dark line on page 8 / 16, indicates where the fabric collar can be placed around the top of the pattern. This is an arbitrary placement; the final placement will be made according to the final design and engineering requirements. The collar is removable and reusable. Note that the pattern shown on page 8 / 16 is represented by a square shape, but the pattern shape can be round (circular), rectangular, or any other shape the final design requires.

[011] The material for producing the structures or components in this patent is based on a woven material that is wrapped around both sections of the tool, either manually or mechanically. The material must cover all external surfaces of both independent sections of the tool. The preferred material is a carbon fiber weave or tape for greater strength and lightness, but it is not limited to this material; the material may be of any woven structure or, indeed, any other suitable material that the final design may require. It should also be noted that, for the component to be formed, the material is wrapped around the tool in its entirety, except where the material is not required in relation to the tools mentioned in this patent and in relation to the final structure or component.

[012] There are several methods that can be used to form the final structure or component once the two sections are compressed together (assuming the material is composed of carbon fiber), such as compression tooling, vacuum bagging, liquid transfer molding, etc., which can be used to form the structure and / or component through the use of this patented tool. For example, if a compression method is used, there will be an outer component that will fit around the entirety of the two tool sections to compress them (the tool sections) and the material inside the outer surface of the tool (and all other parts of the tool section that require material coverage, as seen on page 4 / 16 and page 7 / 12). Petition 870250102381, dated 07 / 11 / 2025, page 12 / 69 5 / 45

[013] It should be noted that there are two compression processes, which can be called, for ease of reference, Process 1, in which the two sections of the tool and, as seen in this patent and, in particular, on page 16, Fig. 1 and Fig. 2, are compressed together by an external compression instrument, as seen on page 10 / 16, Fig. 13b. Note that the same type of methodology as in Fig. 13b is also used to compress the outer “skin” that surrounds the final structure or component produced by Process 1. I call this compression of the outer “skin” Process 2.

[014] On page 12 / 16 and page 13 / 16, the outer material “sleeve / skin” can also be seen when compressed and cured (if the material requires curing) by the inner surface of the compression instrument, as seen on page 10 / 16, Fig. 13b, where the material or “sleeve / skin” is placed between the inner surface of the compression instrument and the outer surface of the final structure or component. This is Process 2 and, as mentioned above, an example of the compression instrument is shown on page 10 / 16, Fig. 13b, No. 44a. Other processes can be used to obtain the same result as above.

[015] Note that Process 1, in addition to combining the two sections of the tool, also compresses the material surrounding the tool where necessary. An example of this is shown on page 4 / 16 and page 7 / 16, No. 24 (the material covering the tool). After the material is compressed, the tool is removed; the tool design is such that it can be removed in a process where each separate section of the tool, as seen on page 1 / 16, Fig. 1 and Fig. 2, is split and removed in the direction shown on page 4 / 16, No. 26, where the arrows show the direction of movement. It should be noted that the tool is shown in the vertical direction, but, depending on the requirements, the orientation of the tool can be vertical, horizontal, or any degree of orientation required. When I refer to the “tool” (unless otherwise indicated), I am referring to both sections of the tool, as seen in this patent, and to the fact that the tool is removed once the Petition 870250102381, dated 07 / 11 / 2025, page 13 / 69 6 / 45 The structure or component is produced by it, leaving each half of the structure or component joined by the junction of the two halves of the tool (these two halves can be seen in Fig. 1 and Fig. 2), forming the final structure or component, as shown in this patent.

[016] The tool allows the creation of buttress structures in the final structure or component, where both horizontal and vertical buttresses allow large and small structures or even components to be joined without any localized stress points that could cause failures in the structure at these joints.

[017] The tool was designed to create, by means of said tool, structures or components where there are no or limited secondary processes that allow structures or components to be built in a “single process” (by which I mean a single process or the fewest possible number of processes), ensuring that these structures and components produced by the tool have internal structures that act as a structural part of the final structure or component and, therefore, it is not necessary to carry out a secondary process to create internal structures that reinforce the component, where these internal structures form the superstructure (“cross-section”) of the final structure and / or component.

[018] Large structures, such as wind turbine blades, are complicated and expensive to produce and are not always effective where there may be localized stress points, potential material bonding problems (e.g., delamination) and structural integrity issues, among several others, such as compression and bending problems, where this patented design can eradicate or minimize these problems, thus optimizing the design and construction of the blades.

[019] To overcome many of these issues, a “single process” (small additional processes are needed if the tool is used as a mold) is, in my opinion, the best possible way to ensure the integrity of the structure and / or component. By creating a “single” process or reducing the Petition 870250102381, dated 07 / 11 / 2025, page 14 / 69 7 / 45 processes to the minimum possible number of steps, as mentioned, many of these structural issues will be overcome and, more importantly, costs will be drastically reduced in some cases, which is a factor as important as structural integrity.

[020] Furthermore, the designed tools show how these internal structures can be formed and interconnected where, as mentioned above, the junctions of the interconnections are seamless and are integrated and formed by the two sections of the tool that join and form the structure and / or component after the material has been molded around each tool. Each structure and / or component can be part of a section (if production in sections is required) of a structure and / or component and can be interconnected without the need to add secondary processes to produce these internal superstructures (cross-sections). The connections between the sections should be glued (if the component or structure does not need to be separated) or connected by other means, such as screws or rivets or other joining methods, if necessary to be removed from each other.

[021] The main structure, as described above and summarized below, consists of two sets of tools that mirror each other's image, except that the buttresses or internal substructure are "offset" relative to the opposite section of the buttresses or internal structure of the tools. Furthermore, the flanges, the internal structure, are offset relative to the internal flanges of the opposite tool so as not to interfere with the section of the tool that enters when both tool sections are placed together. The tool description can be seen below:

[022] Pages 8 / 16 to 15 / 16, including page 3 / 16, show the complete structure and / or component made from the tool or part sections. These sections show how the final structure and / or components are produced and / or how they are joined by the superstructure (formed by the tool) to form a larger structure and / or components or sections of a structure. Petition 870250102381, dated 07 / 11 / 2025, page 15 / 69 8 / 45 larger and / or component. Pages 1 / 16, 2 / 16, 4 / 16, 5 / 16 and 7 / 16 show the tools that produce the structures and / or components. Page 6 / 16, Fig. 5, through page 8 / 16, Fig. 5 shows how the tool can be shaped as a square or rectangle and can be joined to form a square or rectangular structure, thus producing the final structure and / or component after each individual segment (the segments, for example, are shown on page 1 / 16, Fig. 1 and Fig. 2) of the tool is covered with the appropriate material and joined (the two sections of the tool).

[023] Page 4 / 16, Fig. 1 and page 7 / 16, Fig. 7, show how the material, in this case carbon fiber, covers the external surfaces of the structure (for illustrative purposes, only part of the material covering is shown in the tool).

[024] Page 2 / 16 Fig. 2b, where a section of the finished structure can be seen, as can be seen on page 3 / 16, page 9 / 16, page 10 / 16, page 11 / 16, page 12 / 16, page 13 / 16 (view looking directly down at the structure or component), page 14 / 16 and page 15 / 16 (note that these pages show the cylindrical structure). On page 2 / 16, Fig. 2b shows a section of an aircraft fuselage, as an example, where the upper vertical buttress, as can be seen in the finished structure or component on page 11 / 16, Nos. 56 and 58 and on the pages above (except on page 14 / 16, Fig. 17, which does not show the vertical buttresses above or below the horizontal buttresses), is not necessary to have a free and unobstructed area inside the passenger compartment of the fuselage, the lower buttress, as seen on page 9 / 16, Fig. 13, page 10 / 16, Fig. 13b, page 11 / 16, Fig. 14, page 12 / 16, Fig. 15 (component shown in the vertical direction) and page 13 / 16, Fig.16 remains and may be.

[025] designed by cutouts, as shown on page 2 / 16, 58a, to incorporate the aircraft's internal requirements, such as landing gear, electronics, cargo, etc., and on page 54a, the portholes shown represent the passenger compartment or fuselage window, both page Petition 870250102381, dated 07 / 11 / 2025, page 16 / 69 9 / 45

[026] 54a and 58a are for illustrative purposes only.

[027] Page 2 / 16 shows Fig. 1a and Fig. 2b, where Fig. 1a is the same tool section as on page 1 / 16, Fig. 1, except that there are no flanges shown on the tool in Fig. 1a. On page 2 / 16, Fig. 2b shows that there is no need for the lower vertical butt, as shown on page 1 / 16, Fig. 2, No. 9 (assuming that No. 9 is the vertical butt), if No. 9 is the vertical butt, then the tool sections, when combined, will be rotated to the horizontal orientation, rotating to the left in this case, or rotated to the right to be in the horizontal orientation, so the vertical butt that will not be needed is No. 6, otherwise the tool section design is the same as on page 1 / 16, Fig. 2.

[028] Page 8 / 16, Fig. 5 differs from the previous one because it shows how the same design, slightly modified by the cutouts shown in Fig. 5, No. 37a, allows the dividers Fig. 9, No. 36, to fit into the component Fig. 5, No. 31, in the complete structure Fig. 5, forming the superstructure or “cross joint”, as shown in Fig. 9, No. 34, placed inside Fig. 10, where this tool creates the structure that can act as a mold for concrete for the production of caissons or other large structures, but not limited to such large structures. In the case of caissons, the mold will not be removed from the concrete and will remain in place, also forming reinforcement and protecting the concrete.

[029] Page 8 / 16 showing a thick dark line, Fig. 5, No. 42, representing where the fabric collar can be placed around the top of the pattern.

[030] Page 1 / 16, Fig. 1, No. 3, shows double-headed arrows indicating the direction of movement of the two tool sections, showing how they fit together to produce the structure or components, where the two horizontal buttresses (for avoidance of confusion, the horizontal buttress structure spans the entire diameter of each individual tool section and is an integral part of each tool section) shown on page 1 / 16, Fig. 1, Petition 870250102381, dated 07 / 11 / 2025, page 17 / 69 10 / 45 No. 5, move towards each other by suitable external means, as mentioned in this patent, thus securing the material placed in the tool, as shown on page 4 / 16, Fig. 1, No. 24, and also seen on page 7 / 16, No. 24, showing part of the tool covered by the material (in this case, carbon fiber fabric) in

[031] surfaces of the horizontal buttresses facing each other.

[032] The material is compressed by joining both sections of the tool, where the horizontal and vertical buttresses are covered by the material, thus covering the entire surface area of ​​each section of the tool in its entirety, where necessary, to ensure that when the tool sections Fig. 1 and Fig. 2 are joined, they are able to form the final structure and / or component.

[033] Page 1, Fig. 1, No. 1 and Fig. 2, shows the two halves of the tool for making the structure and / or components, No. 2 shows the extended edge or buttress, as per page 9 / 16, Fig. 13 No. 49, also as seen in Fig. 13, No. 49 shows that the corners of the buttress are at right angles, this is only for illustrative purposes, this edge, as with all edges, can be at a right angle or curved (rounded) to any degree of the final structure and / or component produced from the tool, as shown on page 3 / 16, Fig. 3, page 9 / 16, page 10 / 16, page 11 / 16, page 12 / 16, page 13 / 16 and page 15 / 16 (note that on page 15 / 16, the lower vertical buttress is not shown).As shown on pages 3 / 16 and pages 10 / 16 to 15 / 16 (except page 14 / 16), there are two sections joined together forming a final structure or component; in these drawings, the final structure or component is shown as a cylinder, however the tool can be conical, square, ellipsoidal, spherical, etc. Therefore, the internal horizontal and vertical structures form a cross-section shown in this patent and, in particular, on pages 9 / 16 to 15 / 16 (note that page 15 / 16, Fig. 18, does not show the lower vertical buttress) except page 14 / 16, and the tool that produces these sections and the final shape of the final structure and / or component (tool). Petition 870250102381, dated 07 / 11 / 2025, page 18 / 69 11 / 45 shown on page 1 / 16), will then be molded / designed accordingly and will compensate to produce any of the aforementioned shapes, as shown in the thick dashed line on page 15 / 16, Fig. 18, No. 84, which clearly shows that the shape of the structure and / or component is that of a cone and, this being the case, both the internal buttresses and the flanges of each tool will also taper to form the conical shape, which will also be true for the aforementioned shapes of a globe or a cube or a cylinder, etc. Please note page 1 / 16, base of Fig. 2 not shown. Page 1 / 16, Fig. 1, No. 9, section (buttress) fits into Fig. 2, No. 14, (where No. 14 is also part of and perpendicular to the horizontal buttress) of the flange, moving within the flanges Fig. 2, No.

[034] 14 en° 14h. and where buttress no. 6 fits into the flanges of Fig. 1, No. 15 and 14h (where No. 14h is the movable flange), where these two sets of flanges, No. 14 / No. 14h and No. 15 / No. 14h, are part of the horizontal buttresses Fig. 1 and Fig. 2 No. 5 (flange No. 14h is connected to the horizontal buttress, as shown on page 5 / 16, Fig. 2a) and perpendicular to the horizontal buttresses. Furthermore, it can be observed that on page 1 / 16 No. 6 and No. 9, and as can be clearly seen on page 3 / 16 Fig. 3, No. 22, the buttresses are perpendicular to their corresponding horizontal buttresses and are also part of the horizontal buttresses.

[035] Page 1 / 16, Fig. 1, No. 16 shows the cut in buttress No. 9, to allow this buttress No. 9 to fit into the opposite tool Fig. 2, so as to allow buttress No. 9 to fit over the male entry sections shown in No. 11, in this case Fig. 2. The same applies to buttress No. 6, allowing buttress No. 6 to fit over the male section No. 11 of Fig. 1. This can be clearly seen in isolation on page 3 / 16, Fig. 3d. The male section No. 11 is not shown on page 1 / 16, Fig. 2, but can be clearly seen on page 3 / 16, Fig. 3, of the finished structure or component produced by joining the two halves of the tool (Fig. 1 and Fig. 2).

[036] Page 1 / 16 Fig. 1 No. 12, cut to allow the male section of Petition 870250102381, dated 07 / 11 / 2025, p. 19 / 69 12 / 45 input tool, as shown on page 12 / 16. Fig. 15, section Fig. 3b no. 63, to enter the female section of page 12 / 16 Fig. 15, section Fig. 3a.

[037] The internal structure, page 1 / 16 Fig. 1 No. 15 / No. 14h and No. 14 / No. 14h, showing the flanges to accommodate the buttresses of Nos. 6 and 9. Page 3 / 16, Fig. 3, No.

[038] 19 and 20 show the vertical buttress of the finished structure and / or component. The horizontal buttresses on page 3 / 16 are represented by No. 17, No. 17 of Fig. 1, where buttress No. 9 is part of, shows the internal buttresses of the final structure or component joined together, forming a bridge between the two components and formed by the tool, when the tools (as seen on page 1 / 16, Fig. 1 and Fig. 2) are placed together to form the final structure or component.

[039] Page 3 / 16, Fig. 3, No. 21 shows the internal horizontal buttresses of Fig. 2, (where buttress Fig. 2, No. 6 is part of), of the finished structure or component.

[040] Page 3 / 16 also shows the finished component, as do page 6 / 16, page 8 / 16 and pages 9 / 16 to 15 / 16 (page 14 / 16 shows only the horizontal buttresses, in cases where vertical buttresses may not be required). The buttresses in the tool section (Fig. 1) create the structural part of the final structure or component, allowing the buttress on page 1 / 16, Fig. 1 No. 9 and Fig. 2 No. 6 to slide between the two respective female flanges, forming a fitting that allows the material covering buttresses No. 6 and No. 9 to be firmly compressed against the inner walls of female flanges No. 15 and No. 14, where flanges No. 14h are movable in order to compress the buttresses, since buttresses No. 6 and No. 9 pass through the entire depth of their corresponding flanges No. 15 / No. 14h and No. 14 / No.

[041] 14h, respectively, and the tools Fig. 1 and Fig. 2 are connected to each other, forming the final structure and / or component.

[042] Therefore, the final structure and / or component has the superstructure Petition 870250102381, dated 07 / 11 / 2025, page 20 / 69 13 / 45 final internal structure formed by the tool sections, without the need for secondary processes to produce these internal structures.

[043] Page 3 / 16, Fig. 3, Nos. 19 and 20 shows how the vertical buttresses of page 1 / 16, Fig. 1, Nos. 9 and 6, respectively, connect to the structure of Fig. 1, No. 4 and are part of the internal structure of the finished structure and / or component. In addition, the internal structure is also part of the horizontal buttresses, structure Fig. 1, No. 5.

[044] Page 1 / 16, Fig. 1 and Fig. 2 show how buttresses No. 9 and No. 6 fit into flanges No. 14, No. 14, No. 15, No. 14h, respectively, where page 1 / 16, Fig. 2, No.

[045] 6 fits inside flange Fig. 1, no. 15 and no. 14h, which will be shown on both sides of the buttress of Fig. 2 no. 6. and where Fig. 1, no. 9 fits inside flanges no. 14 and no.

[046] 14h, which will be on both sides of the buttress of Fig. 2 no. 9. It should be noted that what is shown on Page 3 / 16 is the finished component. However, the terminology for buttresses remains the same, whether for the tool or for the final structure and / or component. Note that the final structure or component will not have flanges, which are only part of the tool and are related only to the tool sections or when the tool joins to form the final structure or component.

[047] Page 3 / 16, Fig. 3, No. 17, also shows the two horizontal buttresses joined together, connecting the two independent tool structures of page 1 / 16, Fig. 1 and Fig. 2 and of page 2 / 16, Fig. 1a and Fig. 2b to form the final structure or component, as shown on page 3 / 16, page 6 / 16 and page 8 / 16, Fig. 5, as also shown on page 9 / 16, Fig. 13, page 10 / 16. Fig. 13b, page 11 / 16, Fig. 14, page 12 / 16, Fig. 15 and Fig. 15c, page 13 / 16, Fig. 16, page 14 / 16, Fig. 17 and page 15 / 16, Fig. 18. Page 3 / 16, Fig. 3, No. 18 shows the cutouts in the horizontal and vertical buttresses shown on page 1 / 16, Fig. 1 and Fig. 2, No. 12, where Fig. 3, No. 18 shows the cutouts once the two sections of the tool are joined to form the structure. Petition 870250102381, dated 07 / 11 / 2025, page 21 / 69 14 / 45 or final component (as seen in Fig. 3).

[048] Page 3 / 16, Fig. 3, No. 23, where the buttresses meet the external structure of the finished structure or component formed by the tool (the opposite meeting of the buttress and the internal structure of the finished structure or component is not shown) and also shown on page 8 / 16, up to page 15 / 16, except on page 14 / 16, where only the horizontal buttress is shown.

[049] Page 1 / 16, Fig. 1, No. 12 shows cutouts to allow the male section of a secondary structure, as shown on page 1 / 16, Fig. 1, No. 11 (the male section), and also on page 12 / 16, Fig. 15, No. 63, and on page 14 / 16, Fig. 17, No. 71, allowing a secondary structure to enter the female section of the primary structure; for this patent, the primary and secondary structures are defined as a section in Fig. 3a (primary structure) and section in Fig. 3b (secondary structure). These cutouts allow the horizontal substructure or buttress to enter the secondary structure or component to allow the finished structure or component to join and connect these structures or components. These cutouts can also be clearly seen on pages 2 / 16 to 15 / 16 (except on page 3 / 16) and on page 12 / 16, Fig. 15a, No. 13, and on page 14 / 16, Fig. 17, No. 74, where on page 14 / 16 there is no vertical buttress.

[050] For clarity, the cutaways (not to scale) accommodate the male entry section of any secondary structure and / or component, where the secondary structure or component can be seen on page 12 / 16, Fig. 3b, No. 63, where Fig. 3b is a secondary structure that can also be seen on page 11 / 16 and on page 14 / 16, Fig. 17 No. 71.

[051] Page 4 / 16, Fig. 4, No. 26, the arrows show the (vertical) directions of tool displacement in the removal of the final structure and / or component, the final removal method will be decided in the final tool design.

[052] Page 4 / 16, Fig. 4, No. 25 The upper edges / surfaces must not be covered so that the tool can be removed from the component; Petition 870250102381, dated 07 / 11 / 2025, p. 22 / 69 15 / 45 the tool will be moved vertically, away from the structure and / or component if the structure and / or component is vertical, or horizontally, away from the structure and / or component if the structure and / or component is horizontal, or at any other angle relative to the vertical or horizontal. It should be noted that, depending on the final design of the tool, it may be removed by other methods.

[053] Page 4 / 16, Fig. 4, No. 24, shows how the outer surface areas should be covered with a woven or other suitable material. All outer surfaces should be covered except for open or cut-out areas, as shown. Note that in this Fig. 4 No. 24, not all outer surfaces have been covered; the covered surfaces show only a proportion of the covered outer surface area. This is purely for illustrative purposes, to show that open and cut-out areas should not be covered. Both sections of the tool's outer surfaces will also be covered in the same manner. Note that if, for structural reasons, the buttresses and the necessary surfaces can be covered with a structurally more robust material, such as carbon fiber, then the final outer skin / sleeve can be covered with a lower-cost material, such as fiberglass or even high-strength canvas.It should be noted that in some cases, the outer layer / sleeve will not be necessary because a single section, such as that in Fig. 3a, may represent a complete structure or component that will not need to be attached to any other secondary structure and / or component. It should also be noted that the sleeve / layer may not be necessary if several sections are interconnected, depending entirely on the final project requirements.

[054] Page 5 / 16 Fig. 2a shows how, if necessary, the buttress can be designed so that the flanges (only one needs to be moved) can be moved perpendicularly / 90 degrees in relation to the entry buttresses shown on page 1 / 16, Fig. 1 and Fig. 2, No. 9 and No. 6, respectively. This allows the entire flange to compress against the entry buttresses No. Petition 870250102381, dated 07 / 11 / 2025, page 23 / 69 16 / 45 en° 9. The flange Page 5 / 16, Fig. 2a n° 14h can be connected by “pistons”, as can be seen in n° 14b. These pistons connect the main body of the tool, as can be seen in Fig. 2a, to the movable flange n° 14h in Fig. 2a. The reinforcements seen in n° 14c are connected by a bar (or appropriate systems), as shown in n° 14g. The reinforcements move in both directions of travel, approaching and moving away from the tool. N° 14e shows the reinforcements in the open position, as well as the horizontal flanges, and n° 14f shows the reinforcements in the closed position, as well as the horizontal flanges when closed, as shown in n°

[055] Figure 14d shows the supports in the open position within the outer section of the tool. The outer sections of the tool can be seen on page 1 / 16, figures 1 and 2, number 4, and on page 2 / 16, figure 2, number 4, for example. The outer section of the tool can be seen in an enlarged image on page 5 / 16, Fig. 2a, which also shows the support within the outer section of the tool, as shown on page 1 / 16, Fig. 1 and Fig. 2, No. 4 (the outer section of the tool). When the supports are closed, it (flange 14h) travels the necessary distance towards flange 14 and flange 15. The double-headed arrow shown on page 5 / 16, Fig.Figure 2a, No. 14i, shows the direction of displacement in which the flange compresses the material (in this case, carbon fiber) to the necessary pressure between the flanges and the vertical buttresses, so that the carbon fiber material can be heated and cured and, when cured, the flanges can be separated by the supports when they (the supports) move to the open position. It should be noted that, to open and close the buttress, a ratchet mechanism is designed into the outer sections of the tool, or a high-pressure air system, or other currently available methods.

[056] Page 5 / 16, Fig. 2a, No. 14a shows the space in which the reinforcements move; note that the reinforcements are inside guides (not shown) where the reinforcements are under pressure as they move to their closed position by suitable mechanisms within the guides. The reinforcements (not shown) are Petition 870250102381, dated 07 / 11 / 2025, page 24 / 69 17 / 45 pushed open, as can be seen on page 5 / 16, Fig. 2a, No. 14c, and will remain in the open position until forced closed by suitable mechanisms, such as ratchets or compressed air systems, which are an integral part of the tool's outer wall. The flange can be partially seen on page 5 / 16, Fig. 2a, No. 14h. No. 14k shows the double-headed arrow representing both directions of displacement of the reinforcements from the open to the closed position and vice versa. Fig. 2a, No. 4 shows the tool's outer wall, as seen on page 1 / 16, Fig. 1 and Fig. 2 No. 4.

[057] It should be noted that the mechanism shown on page 5 / 16, Fig. 2a, is presented for illustrative purposes, so that the reader can see how the 14h flange movement mechanism works. In the final design, these mechanisms will be hidden in the plan view and side view and will not interfere with covering the tool with the necessary material, when required. Note that the connecting rods between the buttresses may be visible, and it should also be noted that these connecting rods can be split to remove the tool when the structure or component is complete. As mentioned earlier, the movement of the 14h flange can be driven by other suitable means that will be incorporated into the final tool design.

[058] Page 8 / 16, Fig. 5 shows the structure produced by the tool for the possible construction of structures such as low-cost housing or warehouses produced rapidly or even hospitals; there is a great need for cheap, fast and affordable housing in the UK and globally, the main structure of the building can be produced in a single process. If they are residences or hospitals, etc., all the plumbing and electricity can be added in secondary processes. Currently, this patent is considering a maximum structure size (this may change in the future) due to the rapid tooling, of about 25 m in height, which will depend on the tooling design. However, as can be seen in this patent, the smaller height of Petition 870250102381, dated 07 / 11 / 2025, p. 25 / 69 Each 18 / 45 structure can be joined together to achieve an estimated height of 25 meters. This would give a total floor area of ​​25m x 25m = 625m. As the height could be 3m, the building can be divided into levels, giving a ceiling height of 3m (or higher or lower if necessary). If used for housing, each level (vertically) can be easily divided into 625 square foot apartments, comfortably accommodating a family of four, allowing for ten apartments per floor; 8 floors in total, with approximately 3m height. This would mean each structure can accommodate 40 people per floor, accommodating 320 people per structure. Ten structures would accommodate 3,200 people, or 100 structures would accommodate 32,000 people, enough to provide immediate accommodation in a disaster zone such as an earthquake, flood, or any other disaster zone.They can be produced in a few hours and shipped if made 25 meters high, or transported by air if produced 9 meters high, anywhere in the world where assistance is needed. Since the tool can be manufactured in any size up to 25 meters, as mentioned, the size of the tool can very well be increased; the width and height of the tool can be produced to construct the finished structure (in this case, housing) so that the finished structure can fit into a fast means of transport, such as aircraft.

[059] These can be semi-permanent or permanent structures. If they are permanent, they can be clad on the outside to adapt to the surrounding natural environment (note that carbon fiber has to be clad on the outside and inside to protect and insulate the building / structure). Thus, to adapt to the natural environment, as mentioned above, the structure can be clad with wood, for example, in a country where houses are predominantly built of wood.

[060] When necessary, cut-out doors and windows can be introduced, and the space can be divided by removable walls, so as to make the rooms as large or small as needed. In the case of Petition 870250102381, dated 07 / 11 / 2025, p. 26 / 69 For 19 / 45 dwellings, relatively small spaces are needed, whereas in the case of warehouses or hospitals, larger open spaces may be required. Since all structures can be interconnected when necessary, both vertically and horizontally, tall buildings can be produced quickly and at low cost, particularly in regions where buildings are prone to earthquakes or where buildings are not constructed with a high level of structural integrity, leading to the collapse of skyscrapers or tall buildings.

[061] Page 8 / 16, Fig. 5, No. 37 shows other possible buttresses and also No. 37a shows the cross-section. Additional buttresses can be produced by the tool if necessary for greater structural integrity / space division.

[062] Page 6 / 16, Fig. 5, No. 28, shows the male section, which can be placed on a corrugated sandwich material foundation, Fig. 5, No. 29 (if in a seismic zone) or other methods where the material or foundation is robust enough to support the entire structure but can absorb additional tremors. The entire structure, including the corrugated sandwich structural material (or other suitable structure that is technically available), can then be fixed in concrete or other suitable material.

[063] Page 6 / 16, Fig. 5, No. 30 shows the extension of these buttresses which can be extended, in this case laterally, so that buttress No. 30 can enter the neighboring structure of Fig. 6, No. 32. The buttress of Fig. 5, No. 30, will be connected by suitable means to the buttress of Fig. 6, No. 32, as described on page 15 / 16, Fig. 18, No. 82. Note that the buttress of Fig. 5, No. 30, is shown partially entering the neighboring structure of page 6 / 16, Fig. 6, and passing through part of the buttress shown in Fig. 6, No. 32, showing the complete structure of the neighboring structure, for illustrative purposes.

[064] Page 6 / 16, Fig. 5, No. 27, shows other possible buttresses, the dashed lines show the possible position of the other buttresses, the solid lines represent the current position of the buttresses. Petition 870250102381, dated 07 / 11 / 2025, page 27 / 69 20 / 45

[065] Page 6 / 16, Fig. 6, No. 32, complete structure “Fig. 6 (shown partially) which can be connected to any other complete structure(s) and / or components.

[066] Page 6 / 16, Fig. 6, No. 33 shows the vertical buttress of the structure or neighboring components, the buttress is clearly seen on page 3 / 16, Fig. 3, No. 20.

[067] Page 6 / 16, Fig. 5, No. 31, complete structure or component shown.

[068] Page 7 / 16 shows the two sections of the tool, one of which (Fig. 7) shows partial external surfaces covered with material, as also shown on page 4 / 16, Fig. 1, No. 24.

[069] Page 8 / 16, Fig. 9, shows a very simple “cross joint” (not to scale) where the divider Fig. 9, no.

[070] 36, crosses the buttress forming a cross. Page 8 / 16, Fig. 9, is shown in isolation, showing how the buttresses join. Page 6 / 16, Fig. 5, No. 27, shows the buttresses before the placement of the dividers. Page 8 / 16, Fig. 5, No. 37a shows cutaways of Fig. 1, No. 6, representing the buttress (the cutaway of No. 37a is not shown on page 1 / 16, Fig. 1, No. 6) so that the divider Fig. 9, No. 36, can slide into it; buttress No. 6, forming the “cross joint”, as shown on page 8 / 16, Fig. 9, No. 34. The divider Fig. 9, No. 36, crossed dividers are not shown. Note that there may be several dividing beams (note that the dividers should not be confused with buttresses) placed in the complete structure Fig. 5, No. 31, depending on the structural strength required or, in the case of caissons, where the entire structure acts as a container / mold for the concrete poured into it.I foresee that, for example, if the coffin has a base of 25 meters by 25 meters and a height of 25 meters, the dividers will form a grid section forming "cells" of 2.5 m x 2.5 m x 25 m, very similar to a chessboard if we look at it in "plan" and where they (the dividers) are separated by about 2.5 meters, for example (the distance between them depends entirely). Petition 870250102381, dated 07 / 11 / 2025, page 28 / 69 21 / 45 of the calculations and requirements of the structural engineers) and also the number of buttresses can be increased to take into account the necessary number; to be eight, if they are separated by about 2.5 meters in this case. The number of partitions and the quantity of buttresses required depend on the final design and the required structural integrity of the final caisson, as mentioned above. The structure Fig. 5, No. 31; Complete structure, Fig. 5, in the case of caissons, is used not only as a mold for the caissons, but also to give the caissons, through this grid structure, the necessary structural strength and integrity; the structural strength of carbon fiber replaces steel, with all the advantages (which I will not elaborate on in this patent, because there is sufficient data publicly available) that carbon fiber brings when replacing steel whenever possible.

[071] Page 8 / 16, Fig. 9 Transverse dividers are shown. Fig. 12, No. 39, shows a 3D section of the grid created by posts made of carbon fiber composite or other suitable material that are placed through the structure Page 8 / 16, Fig. 5, and in the complete structure Page 8 / 16 Fig. 10. Fig. 12 No. 39 (internal 3D sectional view of Fig. 10). Fig. 5, No. 41, shows each section (in this case, 100 in total) of the columns produced by the dividers within the tool of Fig. 5. Fig. 11 shows a side sectional view. Fig. 11, No. 38, also shows the grid produced by the posts made of carbon fiber composite or other suitable material as a side view. Figure 10, No. 40, also shows rows of posts made of carbon fiber or other suitable material that act in two ways, but are not limited to: 1) They act as structural resistance for the concrete and 2) They connect the concrete pillars. In this example, there are 100 interconnected concrete pillars, thus providing the concrete pillars with additional structural strength. Each concrete pillar is separate, and if one fails, it does not affect any other pillar, thus keeping the entire structure extremely stable. Another advantage is that the entire concrete structure is encased in a carbon fiber composite structure, thus protecting the... Petition 870250102381, dated 07 / 11 / 2025, page 29 / 69 22 / 45 concrete.

[072] Page 8 / 16, Fig. 9, No. 35, also shows the carbon fiber composite posts or other suitable material as a cutaway view of one of the grid sections, the grid is shown only from two sides, while the other two sides are shown open for illustrative purposes only.

[073] Holes for carbon fiber composite posts or other suitable material may be cut by laser or water jet cutters or by other suitable means. The holes must have an enlarged fit with the posts and the posts are glued to the holes by suitable bonding agents, if necessary.

[074] The number of carbon fiber composite posts or other suitable material and their respective distribution within the “cells” created by the dividers and buttresses will be determined by structural engineers and are not part of this patent. Similarly, the thickness of the carbon fiber composite posts or the combination of materials to manufacture the carbon fiber composite posts or other suitable material is again subject to final structural analysis and design.

[075] Page 9 / 16, Fig. 13, No. 43, where the buttress is shown in the horizontal position (the structure Page 9 / 16, Fig. 13, shows the entire structure and / or component in the horizontal position).

[076] Page 9 / 16, Fig. 13, No. 48, the dashed line structure shows part not only of the structure or component formed in Fig. 13, but also, as can be seen on page 10 / 16, page 11 / 16, Fig. 14, No. 58, page 12 / 16, Fig. 15, No. 59 (No. 59 shows the cross-section formed by the horizontal and vertical buttresses) up to No. 65, page 13 / 16, Fig. 16 No. 66, page 14 / 16, Fig. 17, (Fig. 17 does not show the vertical buttress) and page 15 / 16, Fig. 18. However, these pages do not show that the component representing each section of the tool can have its internal structure positioned so that the two internal vertical and horizontal structural buttresses are spaced apart. Petition 870250102381, dated 07 / 11 / 2025, page 30 / 69 23 / 45 within the internal structure (buttresses) of a connecting structure or component, for example, on page 11 / 16, Fig. 14, Nos. 56 and 58, where the distance traveled by the internal buttresses can be seen.

[077] internal buttresses overlapping the internal buttresses of the connected secondary structure or component. Section Fig. 3a connected to Section Fig. 3b, where the buttresses overlap the buttresses of the connected Section, in this case Fig. 3a, where Fig. 3a is connected to Fig. 3b, and where No. 80 shows the overlap and connections of the vertical buttresses of Section Fig. 3a and Section Fig. 3b. The overlap distance of the buttresses, whether vertical or horizontal, will depend entirely on the structural requirements of the final design of the structure or final component.

[078] The internal horizontal structure, where the buttresses are offset from the center, shown by dashed lines, the external material, such as the carbon fiber composite, was not shown on pages 9 / 16 to 15 / 16, but was partially represented by thick black lines of the final structure and / or component. Note that on pages 9 / 16 to 15 / 16, the structures are described and shown as a cylinder ee for illustrative purposes, and may be conical or tapered, as in turbine blades, designed to suit the application.

[079] Page 9 / 16, Fig. 13a, shows how No. 53 overlaps No. 47. The horizontal buttresses are also shown on page 14 / 16, Fig. 17, where section Fig. 3a, No. 72 fits over section Fig. 3b, No. 70.

[080] Page 9 / 16, Fig. 13a. No. 44 shows the outer layer or sleeve.

[081] Page 9 / 16, Fig. 13a, No. 50 shows the vertical inner buttress leveled with the outer layer or sleeve.

[082] Page 1 / 16, Fig. 2, No. 6 The section (buttress) fits into Fig. 1, No. 7, in the opening that allows buttress No. 6 to enter and remain between the two flanges shown on page 1 / 16, Fig. 1, No. 15 / 14h. Furthermore, the opposite section of Fig. 1, No. 9, of the buttress fits into Fig. 2, No. 14 / 14h, on the two flanges. The flanges, as shown in numbers 14 and 14h, and also flanges numbers 15 and 14h, where it can be seen that these two buttress sections Petition 870250102381, dated 07 / 11 / 2025, page 31 / 69 24 / 45 are offset from each other so that they do not collide when the two halves of the tool combine to form a single tool, in order to produce the final structure and / or component.

[083] Page 1 / 16, Fig. 1, No. 8 and also shown in Fig. 2, showing the flange sections by dashed lines. The double-headed arrows in Fig. 1, No. 3 show how they fit into their respective sections. Note that No. 8 should not be confused with the flange sections shown in Fig. 1, No. 15, No. 14h. They are the same flanges, except that No. 8 shows the flanges as dashed lines to show the flange profile within both tool sections, Fig. 1 and Fig. 2.

[084] For greater clarity, see in isolation on page 3 / 16, Fig. 3c, how the buttress Fig. 3, no. 9, (no.

[085] 19, in Fig. 3 and Fig. 3c, is the same buttress as in Fig. 9, except that it is in situ (in the completed component) and fits into flanges Fig. 3c, No. 14 and No. 14h. These flanges can be seen on page 1 / 16, Fig. 2, No. 14 and 14h, and on page 2 / 16, Fig. 2.

[086] Page 1 / 16, Fig. 2, No. 10, shows the openings where the buttress enters the tool wall. As can be seen on page 13 / 16, Fig. 16, No. 67, the final structure or component, where it can be seen that the internal buttress is level with the wall of the final structure and / or component and the inner surface of the sleeve / skin will be bonded to the outer surface (the inner surface is the surface facing the surface of the final structure or component) of the finished structure or component. It should be noted that Fig. 16 shows the final structure and / or component that is covered by the sleeve / skin.

[087] Page 1 / 16, Fig. 1, No. 11 shows the step that can be described as the male section of the tool, so as to allow a completed structure and / or component, produced by the tool and covered by the necessary material, such as carbon fiber or other suitable material, to fit into a completed secondary structure and / or component, as shown on page Petition 870250102381, dated 07 / 11 / 2025, page 32 / 69 25 / 45 12 / 16, Fig. 15, and where No. 63 shows the male section of Section Fig. 3b, fitted into the female section of Fig. 15 Section Fig. 3a, as can also be seen on page 11 / 16, page 12 / 16. Page 13 / 16; Fig. 16 shows a telescopic view of the two structures or components when they are joined. Pages 14 / 16 and 15 / 16 show the two components joined after the final structure and / or component emerges from the tool that forms the structure or component needed to be manufactured; again, the material that produces these structures and / or components will be decided by the final design and the technical and structural requirements of said structure and / or component. Note that, for my patent, the preferred material is carbon fiber.

[088] All internal structures have the diameter of the corresponding structure or component, unless the internal structure has been partially cut out to allow a secondary structure to be joined to the original structure; the cutouts are shown on pages 1 / 16 to 14 / 16. Page 12 / 16, Fig. 15a, No. 13, the cutout is shown in isolation. Page 13 / 16, no cuts are shown, page 3 / 16 Fig. 3, No. 18, page 9 / 16, Fig. 13, No. 52 shows the cutout to allow Section Fig. 3b, page 14 / 16, to move to Fig. 3a, page 14 / 16, which can also be clearly seen on page 15 / 16, Fig. 18, No. 81, the cutout in the horizontal buttress and as clearly shown on page 14 / 16, Fig. 17, No. 74a, showing the cut of the horizontal buttress in clear detail, within section Fig. 3b, allowing section Fig. 3a to move to section Fig. 3b, as shown on page 14 / 16, No. 73, and as shown on page 15 / 16, Fig. 18, the buttress no.° 81 of section Fig. 3a can be seen within section Fig. 3b, where Fig. 3a is shown connected to Fig. 3b.

[089] Page 9 / 16, Fig. 13, No. 51 shows the cutout to allow the vertical structures on page 15 / 16, Fig. 18, No. 81 to move, as shown in Fig. 18, No. 79.

[090] Page 9 / 16, Fig. 13, No. 47, shows the internal horizontal structure (buttress), as does Fig. 14, No. 56 and No. 58, which shows the internal buttress or Petition 870250102381, dated 07 / 11 / 2025, page 33 / 69 26 / 45 substructure in a vertical position connected to structure no. 58, where no. 58 shows how they fit perfectly into the internal structures or buttresses, forming a cross-section by both the vertical buttress and the horizontal buttress which are interconnected to traverse the length of the structures Fig. 3a and Fig. 3b. It can be seen that the internal vertical buttresses of Fig. 3a traverse an arbitrary length of the internal Fig. 3b; the final length will be defined by the structural requirements of the final structure and / or component. This can be seen on page 11 / 16, Fig. 14, section Fig. 3a, no.

[091] 56, where no. 56 can be seen either by the continuous line or by the dashed line that runs through an arbitrary length of Fig. 14, section Fig. 3b, no. 58, the vertical buttress of section Fig. 3b; the two buttresses of section Fig. 3a and Fig. 3b can be fixed or glued by a suitable methodology.

[092] Page 9 / 16, Fig. 13, No. 46, shows the internal structure of Fig. 14, page 11 / 16; the horizontal buttress, as can be seen on page 11 / 16, No. 58b and No. 45, page 9 / 16, Fig. 13, for example, is shown as being placed in the center, this is only for illustrative purposes and can be “shifted” for design specifications, such as for an aircraft floor, where the structure needs to be shifted from the central position, as shown in Fig. 13, No. 47 (the central position), by dashed lines.

[093] Page 9 / 16, Fig. 13, section Fig. 3a, buttress no. 45, overlaps (not to scale) the internal structure or buttress of the structure and / or component of section Fig. 3b Fig. 13, no. 47; section Fig. 3b not shown here, but (section Fig. 3b) as shown on page 11 / 16, Fig. 14, no. 58, so as to join (by external fasteners or glue) to a second structure and component similar to those shown in Fig. 14, where section Fig. 3a and section Fig. 3b are shown as joined by suitable means to form the finished structure and / or component (the material of which the structure or component is made is not shown), as shown on page 12 / 16, Fig. 15, for example. Note that, depending on where sections such as the section of Fig. 3a and the section of Fig. 3b, Petition 870250102381, dated 07 / 11 / 2025, page 34 / 69 27 / 45 which may be part of the final structure and / or component, the positioning of the internal structures, as shown on page 14 / 16, Fig. 17, No. 72, may be above or below page 14 / 16, Fig. 17, No. 70; however, the functionality of the combination (in this case, the horizontal buttress) remains the same. Therefore, the position of page 9 / 16, Fig. 13, No. 45, above page 9 / 16, Fig. 13, No. 47, or below No. 47, depends exclusively on the final design.

[094] Page 9 / 16, Fig. 13, No. 48, the internal structure of the buttress in dashed line shows not only the structure formed as on page 3 / 19, page 6 / 16, page 8 / 16 to page 15 / 16. Page 14 / 16, Fig. 17, does not show the vertical buttresses, as seen on page 3 / 16 and on pages 9 / 16 to 15 / 16. The structure and / or component may have its internal structure positioned in such a way that the two structures and / or components (each formed by the combination of the two separate tools, as on page 1 / 16, Fig. 1 and Fig. 2, forming a larger structure and / or component) these structures or components formed by said tool may be combined by their respective internal structures, as shown in this patent. The internal buttresses of a structure and / or component may overlap the internal buttresses of a secondary structure or component, as can be seen, for example, on pages 9 / 16, Fig. 13 and Fig. 13a, pages 11 / 16, Fig. 14, No. 58, page 14 / 16.Fig. 17 (note that only the horizontal position of the buttress is shown on page 14 / 16) and page 15 / 16, Fig. 18. However, as mentioned in this patent, the overlap of the internal buttresses, in this case the structure and / or component of sections Fig. 3a and Fig. 3b internal buttresses, can be 100% of the length of the structure or components and extended where necessary to interconnect with other sections, as shown. Note that the final structure and / or shape of the component are designed as a cylinder for illustrative purposes only, and may be conical or tapered, as in turbine blades, designed to suit the application.

[095] Page 10 / 16 of Fig. 13b, No. 44a, shows that when the two halves of the outer tool semicylinders are joined, the weight (or by Petition 870250102381, dated 07 / 11 / 2025, page 35 / 69 28 / 45 external pressure not shown) of the two halves will compress the material and therefore cure the material covering the final structure or component; if the material needs heating, a suitable mechanism will be designed to heat the tool, which is not part of this patent; the process of combining the two halves of the two sections is called Process 1.

[096] Page 10 / 16 Fig. 13b, No. 44b, this section of the external tool system can be moved to compress the material covering the final structure or component in its entirety, once the two parts of the tool join and thus form the final structure and / or component shown in this patent. The two separate structures or components formed by each section of the tool, as seen on page 1 / 16, Fig. 1 and Fig. 2, to form a larger structure and / or component; note that each separate section, as per this page and this patent and section Fig. 3a and section Fig. 3b, will be covered with the necessary material (when necessary), such as carbon fiber, and once the two sections are produced and covered with the desired material and compressed by the external tool, as seen on page 10 / 16, Fig. 13b, until the material is cured (if the material needs curing), thus producing the final structure or component. The two finished structures Fig.Figures 3a and 3b, as seen on page 12 / 16, Figure 15, for example, can be joined by their corresponding buttresses and by the male section, as seen on page 12 / 16, Figure 15, No. 63, which is the male section of the structure and / or component Figure 3b that enters the section Figure 3a, forming an additional structural joint. It should be noted that the male part of the section Figure 3b will have an enlarged fitting, or as close as possible to an enlarged fitting, when technology allows, when entering the section Figure 3a to join both sections Figure 3a and Figure 3b. The thick black line shown on page 12 / 16, Fig. 15 and Fig. 15a, No. 64, partially shows where the material covering the final structure and component forms, thus, the final structure or component, which can also be defined as the final product (the material will cover the entire final structure and / or component, when necessary, but is not shown in this drawing). Petition 870250102381, dated 07 / 11 / 2025, pp. 36 / 69 29 / 45 page 12 / 16). Note that page 12 / 16, Fig. 15 shows the final product.

[097] The double-headed arrow on page 10 / 16, Fig. 13b, No. 44c, shows the direction of travel of this part of the external compression tool seen as No. 44a and No. 44b; note that this external compression tool design is for illustrative purposes only, showing how the material around the final structure and / or component will be compressed to form the final structure or component by compressing said material of the structure or component; the same method could be used to combine the two sections of the tool to form the final structure or component.

[098] Note that the final structure or component may not need to have an outer sleeve / skin; this will depend entirely on the final design of the structure or component.

[099] Page 12 / 16, Fig. 15a shows a cutaway view of buttress no. 9 or no. 6. For this cutaway view, I used buttress no. 9, as seen on page 1 / 16, Fig. 1. It can be observed that buttress no. 9 in Fig. 15a, like the buttress, once covered with suitable material, will enter the cutout section of the external tool. The cutout can be seen on page 1 / 16, Fig. 2, no. 10, and also on page 2 / 16, Fig. 2, no. 10, before the insertion of the buttress, in this case represented by buttress no. 9, into the external section of the tool.

[100] Note also that page 12 / 16, Fig. 15b, shows the front view of the cutout shown (no. 10), the buttress no. 9 and also the flanges no. 14 and 14h, where 14h is the movable flange for compressing the material (as seen on page 1 / 16, Fig. 1, no. 24), between the flange and the buttress (the material can be seen on page 5 / 16, Fig. 2a) and explained in this patent.

[101] The white line, as shown on page 12 / 16, Fig. 15a, No. 10, where No. 10 shows the gap (which can also be seen on page 1 / 16, Fig. 2) where the counterfort No. 9 enters and becomes flush with the inner surface of the outer material or sleeve / cladding, where, as mentioned, the white line serves only for illustrative purposes, to show where the counterfort enters and joins and is bonded by a suitable bonding agent (glue) to the final material. Petition 870250102381, dated 07 / 11 / 2025, page 37 / 69 30 / 45 described as the outer material of the corresponding section of the tool, forming (once both sections of the tool, as seen, for example, in Fig. 1 and Fig. 2, are joined) the final structure or component, as seen on page 12 / 16, Fig. 15, No. 64, and also where No. 64, for illustrative purposes, shows the edge of the outer material of the final structure and / or component.

[102] Note that page 16 / 16, Fig. 22 shows how the final outer sleeve / skin shown in Fig. 22 is placed on the final structure or component. Other methods may be used, for example, a tape placement machine.

[103] Page 9 / 16, Fig. 13a, shows the internal structures or buttresses and how they overlap, as seen on page 9 / 16, Fig. 13, which shows the buttress of the internal substructure overlapping in both the vertical and horizontal directions. These internal substructures will form a cross-section that may run the entire length of the internal structure or component, if the design of the structure or component so requires. In this illustration, the internal substructure is shown running the entire length of the final structure and / or component with an extended section (edge) so as to connect with another structure and / or component, as described in this patent and on page 11 / 16, Fig. 14, No. 56, the two internal buttresses as per page 13 / 16, Fig. 16, No. 66, page 14 / 16, Fig. 17, No. 70 (which also shows the overlapping of a set of buttresses in the horizontal position) and on page 15 / 16, Fig. 18, No. 80, shows the vertical buttresses of the section Fig.3a and section Fig. 3b, where they are connected by suitable mechanisms, such as gluing or screwing (as can be seen in paragraphs 82 and 83) at their interface.

[104] Page 12 / 16 Fig. 15c, the isolated male section, where No. 63a shows the gap in the male section, the male section is shown in Fig. 15, No. 63, this gap allows the horizontal (No. 62) and vertical (No. 58) buttresses to pass through a secondary structure or component. Petition 870250102381, dated 07 / 11 / 2025, pp. 38 / 69 31 / 45

[105] Page 11 / 16. Fig. 14, No. 58 shown in part by the dashed lines with dots, between the dashed lines represent part of the horizontal structure, as seen on page 14 / 16, Fig. 17, No. 70 of section Fig. 3b. Page 11 / 16, Fig. 14, No. 55, section Fig. 3b, the structure or component is connected to Fig. 14, No. 54, section Fig. 3a.

[106] Note that page 11 / 16, Fig. 14, page 12 / 16, Fig. 15, page 13 / 16, Fig. 16 (Fig. 16 shows a telescopic view, looking down at the center of the structure and / or component) Page 14 / 16, Fig. 17 and page 15 / 16, Fig. 18, show only two sections of a structure and / or component; Fig. 3a and Fig. 3b, but this may be applicable to various sections, such as those of large wind turbine blades, but not limited to them. The structures are shown transparently to show the internal structures of the structure or components.

[107] Page 11 / 16, Fig. 14, No. 57, shows the cuts that allow the section or buttress, as shown in this patent, to fit into section Fig. 3a, page 14 / 16. Page 14 / 16, Fig. 17, No. 74a. Page 11 / 16, Fig. 14, No. 52 shows the stepped connection between the two components, as in page 9 / 16, Fig. 13, No. 52, and also as shown in page 10 / 16, Fig. 13b, No. 52 and page 11 / 16, Fig. 14, No. 52.

[108] Page 12 / 16, Fig. 15, shows a 3D illustration of the finished structure and / or component.

[109] Page 12 / 16, Fig. 15, No. 59, shows the horizontal and vertical buttress forming a cross-section. The overlapping of the incoming buttresses of 3a over 3b (or 3b over 3a) is not shown for clarity in Fig. 15; however, the buttresses in sections 3a and 3b are shown. These overlaps can be seen on pages 11 / 16 to 15 / 16, Fig. 13, Fig. 14, Fig. 16, Fig. 17, and Fig. 18, except on page 10 / 16, Fig. 13b, where only a section of the finished structure and / or component is shown. As noted in this patent, I use the description of section Fig. 3a as overlapping the buttresses of section 3b; however, depending on the design... Petition 870250102381, dated 07 / 11 / 2025, pp. 39 / 69 32 / 45 of the final structure, the buttress sections in Fig. 3b could overlap the buttress in Fig. 3a,

[110] Page 12 / 16, Fig. 15, No. 64, the edge of the outer material (in this case, carbon fiber) represented by the thick line, not shown in its entirety, in order to see the internal structures (horizontal and vertical buttresses)

[111] Page 12 / 16, Fig. 15, No. 62, the horizontal buttress is visible in both sections 3a and 3b. As mentioned earlier, the overlaps are shown on page 11 / 16 to page 15 / 16 and in the following figures Fig. 13, Fig. 14, Fig. 16, Fig. 17 and Fig. 18 and connect with the external structure of the component or finished structure, as seen on page 11 / 16, Fig. 3a, No. 58b, where, for illustrative purposes, I showed the horizontal buttress of page 1 / 16, Fig. 1 and Fig. 2 No. 5, which can be clearly seen in the finished product of page 5 / 16, Fig. 18 buttresses, No. 70 and No. 72, respectively.

[112] Page 12 / 16, Fig. 15, No. 63, the male section of section Fig. 3b fits into section Fig. 3a (female section), as shown on page 11 / 16 on page 15 / 16, Fig. 14, Fig. 15, Fig. 16, Fig. 17 and Fig. 18.

[113] Page 12 / 16, Fig. 15, No. 64 shows the outer sleeve / skin or covering of the final structure and / or component, the final structure or component being formed by the two sections Fig. 3a and Fig. 3b that join together, forming a larger structure, as shown in Fig. 15.

[114] Page 12 / 16, Fig. 15, shows the outer material no. 64, leveled with the buttress shown in the horizontal position, as seen on page 13 / 16, Fig. 16, no. 67.

[115] Page 12 / 16, Fig. 15, No. 60, section Fig. 3a, Fig. 15, No. 61, section Fig. 3b, part of one or more sections added to section Fig. 3a or to section Fig. 3b, in order to connect several sections that may be required for components such as large wind turbine blades approximately 120 meters long, but not limited to these.

[116] Page 13 / 16, Fig. 16, No. 66, the structures of the components, Petition 870250102381, dated 07 / 11 / 2025, p. 40 / 69 33 / 45 as shown on page 3 / 16, page 6 / 16, page 8 / 16, page 9 / 16 to page 15 / 16, which includes Fig. 3, Fig. 5, Fig., Fig. 13, Fig. 14, Fig. 15, Fig. 17 and Fig. 18. However, page 13 / 16, Fig. 16, shows a view directly below the component, where the buttresses are shown in the vertical and horizontal positions and where, on page 9 / 16, Fig. 13a, the internal structure of the buttresses is shown in isolation, so as to have a clearer picture of how the internal structures can overlap each other, the horizontal structure is shown, as on page 13 / 16, Fig. 16.

[117] Page 13 / 16, Fig. 16, shows the internal structures. The substructures or buttresses (shown in the vertical position) shown in Fig. 16, No. 69, may be one, two, three or more, depending on the final design and structural requirements of the final structure and / or component. The substructures or buttresses are described on pages 1 / 16 to 15 / 16 (page 14 / 16, where only the horizontal buttresses are shown). On page 13 / 16, Fig. 16, the vertical substructures or buttresses are shown on both sides of the horizontal substructure or buttress. On page 9 / 16, Fig. 13, the vertical substructure or buttress is shown in part by dashed lines, No. 46, No. 47 and No. 48.

[118] Page 15 / 16, Fig. 18, no. 81, the vertical substructure or buttress of section Fig. 3a, overlapping the vertical substructure of section Fig. 3b, no. 75.

[119] Page 15 / 16, Fig. 18, shows only a vertical substructure or buttress at the top of the horizontal substructure, the lower vertical substructure or buttress is not shown.

[120] Note that page 13 / 16, Fig. 16, No. 67, shows where the surface of the inner substructure buttress is located and is level (aligned) with the outer structure of the final structure or component before the final structure or component is covered by the outer material or sleeve / cladding, if necessary.

[121] Note that page 13 / 16, Fig. 16, no. 68, shows where the two Petition 870250102381, dated 07 / 11 / 2025, page 41 / 69 34 / 45 sections of the structure and / or component are placed one inside the other by an arbitrary length, which is the result of the design of both sections of the tool, as shown on page 7 / 16, Fig. 7 and Fig. 8 (although the shape of the tool is shown on page 7 / 16 as a square) and as shown on page 14 / 16, Fig. 17, No. 70 and No. 71. The penetration length in the secondary component, as shown on pages 11 / 16 to 15 / 16 (except on page 13 / 16), pages 11 / 16 to 15 / 16 show Fig. 14, No. 56, No. 58, Fig. 15, No. 59, No. 62, No. 63, Fig. 16, No. 66, No. 69 Fig. 17, No. 70, No. 72 and Fig. 18, Nos. 77, 78, 80 and 81 will depend on the final project requirements, as will all other substructures and superstructures. Note that, as mentioned earlier in this patent, the overlaps are not shown on page 12 / 16, Figs. 15 and 15b of the structures.

[122] Page 14 / 16, Fig. 17, No. 74a shows the cuts.

[123] Page 14 / 16, Fig. 17, no. 70, lower section not shown, as shown on page 9 / 16, Fig. 13, no. 52.

[124] Page 14 / 16, Fig. 17, No. 74 shows the section of page 14 / 16, Fig. 17, Fig. 3b. Section No. 72 of Fig. 3a fits inside and over section No. 70 of Fig. 3b; horizontal buttress No. 72 fits over horizontal buttress No. 70, but can also fit below horizontal No. 70 if necessary.

[125] Page 14 / 16, Fig. 17 shows how the two sections of the structure and / or component (Fig. 3a and Fig. 3b) fit together, which can also be seen on pages 11 / 16 to 15 / 16; Fig. 14, Fig. 16 and Fig. 18. The internal horizontal structure or buttress on page 14 / 16, Fig. 17, No. 70 and No. 72 shows the overlapping of these horizontal buttresses (No. 70 and No. 72) and how they are joined, the substructure or buttress which may be in the vertical position, also as seen in this patent. Page 14 / 16, Fig. 17, No. 71 shows the internal structure of section Fig. 3b of Fig. 17, where the male section fits into the female section of Fig. 3a. Section Fig. 3b shows only a cross-sectional slice of how the two sections of the final structure and / or component fit together. Petition 870250102381, dated 07 / 11 / 2025, p. 42 / 69 35 / 45 see also page 1 / 16, Fig. 14, page 12 / 16, Fig. 15 (Fig. 15 does not show the overlaps of the 3a buttress on 3b or vice versa), page 13 / 16, Fig. 16, page 14 / 16, Fig. 17, page 15 / 16, Fig. 18.

[126] Page 15 / 16, Fig. 18, No. 80 buttresses or substructure (shown in the vertical position) in section Fig. 3b overlapping each other, i.e., the buttress of section Fig. 3b overlaps the buttress or substructure of Fig. 18, Page 15 / 16, No. 81 of section Fig. 3a,

[127] Page 15 / 16, Fig. 18, no. 76, shows in part the penetration depth of the buttress of section Fig. 3a into sections Fig. 3b of the vertical substructures or buttresses of section Fig. 3a, no.

[128] 81 and the overlap depth of buttress no. 75 of section Fig. 3b.

[129] Page 15 / 16, Fig. 18, No. 79 shows the cut to allow the vertical buttress or substructure of page 15 / 16, Fig. 18, No. 81, of section Fig. 3a to move through a buttress and (in the horizontal position) or substructure, as clearly seen on page 9 / 16, Fig. 3a, No. 51, showing the cross-sections, of Fig. 18, No. 79, also clearly visible on page 14 / 16, Fig. 17, No. 74a and on page 11 / 16, Fig. 14, No. 57, section Fig. 3b. Lower vertical beam or substructure of section Fig. 3a and Fig. 3b not shown.

[130] The sections on page 15 / 16, Fig. 18, No. 77 show the overlap and penetration of No. 80 of section Fig. 3a into section Fig. 3b, overlapping No. 75 and joining the buttress or substructures of sections Fig. 3a and Fig. 3b (shown in this case in the vertical position). The sections are also shown on page 9 / 16, Fig. 13, No. 48, page 11 / 16, Fig. 14, No. 56 and Fig. 3b, No. 58, page 12 / 16, Fig. 15, No. 59 (the overlap is not shown), page 13 / 16, Fig. 16, No. 69 and page 15 / 16, Fig. 18, No. 80.

[131] Page 15 / 16, Fig. 18 no. 78 shows how sections Fig. 3a and Fig. 3b fit together and shows part of the female section that accommodates the male section (the rest of the inner female section of Fig. 18, Fig. 3a not shown). This section is also shown on page 12 / 16 to page 14 / 16; Fig. 15, no. 63, Petition 870250102381, dated 07 / 11 / 2025, page 43 / 69 36 / 45 Fig. 16, no. 68 and Fig. 17, no. 71.

[132] Page 15 / 16, Fig. 18 No. 82, the buttress or substructure (shown in the vertical position) shows the bolts that connect the buttress or substructure to sections Fig. 3a and Fig. 3b. The distribution and number of bolts are for illustrative purposes only and will be confirmed in the final design and the necessary requirements relating to structural integrity.

[133] Page 15 / 16, Fig. 18, No. 83 shows the buttress or substructures (shown in the horizontal position), bolts, the distribution and number of these bolts are for illustrative purposes only and will be confirmed in the final design and the necessary requirements relating to structural integrity.

[134] Page 15 / 16, Fig. 18, No. 81, the buttress or substructure of section Fig. 3a, which may run the entire length of the substructure and / or buttress of Fig. 18, Fig. 3b, No. 75, but is shown only as running the partial length of buttress No. 75. Fig. 18, No. 80, shows the two vertical buttresses of section Fig. 3a and the vertical buttress of section Fig. 3b ( ) and how they overlap along the arbitrary length. The length of the buttress of Fig. 3a, No. 81, will depend on the final project specifications.

[135] Page 15 / 16. Fig. 18, No. 84a shows the horizontal buttresses of section Fig. 3a and the horizontal buttress of section Fig. 3b overlapping over an arbitrary length.

[136] Page 16 / 16 Fig. 19, No. 85, shows a weaving machine that produces 2D or 3D woven material or that can be replaced by a specialized “carbon fiber tape winding machine” that would wind carbon fiber around the tool and the final structure and / or component. In the case of 3D material (in this case, carbon fiber material), the woven material is lattice-shaped so that it can follow the shape of the tool; the double lines in No. 90 represent the woven material. The weaving machine is for illustrative purposes only and is not part of this patent.

[137] Page 16 / 16, Fig. 22, No. 86 shows the 2D side view of the page Petition 870250102381, dated 07 / 11 / 2025, page 44 / 69 37 / 45 12 / 16, Fig. 15, as an example of a produced component and a final weave, once (the woven material) is wrapped around the entire structure or component, Fig. 22, No. 87, shows the direction of movement of the material that will cover the final structure or component shown on page 12 / 16, Fig. 15, as an example.

[138] Fig. 20, No. 92, shows the direction of movement of half the tool. It is important to note that the rotation of the tool must be synchronized with the rotation and material release speed of the weaving machine or tape machine. In the case of the weaving machine, it produces the material as a network shape from the tool.

[139] Note that it may not be essential for the tool to rotate, as more sophisticated tape placement machines can rotate around the tool.

[140] Page 16 / 16, No. 88, shows the central axis of rotations of the material and of the final structure or component or of each individual section of the tool (final structure or component shown in Fig. 22, individual section of the tool shown in Fig. 20 and Fig. 21). In Fig. 20 and Fig. 21, half of the tool is shown, as seen in this patent and, in particular, on page 1 / 16, Fig. 1 and / or Fig. 2, before the tool is combined to form the final structure and / or component. The final structure or component can be seen on page 3 / 16, page 6 / 16, page 8 / 16 and pages 9 / 16 to pages 15 / 16. page 13 / 16 (telescopic view, i.e. looking directly down at the structure and / or component).

[141] The same method of placing the material on the tool or on the final structure or component can be used for square, rectangular or other shapes, however, other methods may be used if necessary.

[142] Page 16 / 16, Fig. 21, No. 89 shows the clamps for securing the material in place and providing tension on both sides of the tool buttress (the tool buttress can be seen on page 1 / 16, Fig. 1, No. Petition 870250102381, dated 07 / 11 / 2025, pp. 45 / 69 38 / 45 9, and also on page 1 / 16, Fig. 2, No. 6). Note that the drawing showing the tool's buttress on page 16 / 16, No. 94, does not indicate whether it is page 1 / 16, Fig. 1, No.

[143] 9 or Fig. 2, no. 6. It simply indicates the buttress and how the material is placed around each section of the tool, whether it is one half of the tool or the other half of the tool.

[144] Page 16 / 16, Fig. 19, No. 90 shows the material of the weaving machine and / or the tape machine, No. 91 shows the direction of material movement.

[145] It should be noted that the weaving machine weaves the material at the same speed as the rotation of the tool, so that the material covers the tool as it rotates, ensuring tension in the material at all times if the weaving machine is not wide enough to cover the entire length of the tool. Therefore, the weaving machine must weave in sections along the length of the tool, ensuring that the weaving is continuous along the length of the tool and that there are no gaps between each section.

[146] However, as mentioned earlier, a tape placement material can be used to place the carbon fiber tape (carbon fiber being the preferred material) and, if this is the case, the tool may not need to rotate.

[147] Page 16 / 16, No. 93, shows the flanges that will accommodate the buttress and tool sections, as shown in this patent and clearly on pages 1 / 16, 2 / 16, 4 / 16, 5 / 16, 7 / 16, No. 14 / 14h and No. 15 and also shown on page 12 / 16, Fig. 15a. showing the flanges in 3D.

[148] This invention addresses and overcomes the problems related to the mass production of large structures by means of a specialized tool design that can be used to produce the components for structures such as, but not limited to, large wind turbine blades. Currently, these types of structures are produced in a long section and, in their largest form, are made of a single, thin, thin material. Petition 870250102381, dated 07 / 11 / 2025, pp. 46 / 69 39 / 45 part, by manual processes that have limited precision with regard to the precise positioning of the material and are time-consuming, laborious and expensive processes, which can result in possible localized stress points, which can result in catastrophic failure of the finished components. This form of production does not lend itself to large-scale automation and, therefore, the number of large structures that can be produced in a single location is very limited. This invention describes the tool that is fundamental to producing the final structure and / or components that depend on structures and / or components made of composite materials, such as carbon fiber composites, carbon fiber being my preferred material with respect to this patent.

[149] My invention, by means of the design of specialized tools, allows these large components / structures to be produced in a single or nearly single process; by this I mean that once the tool has been covered with the desired material, which can again be done in an automated process as shown, the two sections of the tool can be combined to form the component. The combination of the tool sections can also be carried out by a suitable mechanism which is not part of this patent, and again this can be fully automated.Therefore, the entire process can be fully automated, thus overcoming the many inaccuracies associated with a manual process, with the added advantages of lower production costs, shorter production times, and large production volumes, resulting in a lower final selling price, which will ultimately lead to lower energy costs for the consumer (taking turbine blades as an example). The tool design, as mentioned in claim 1 and shown in the patent drawings, can also be used for other large structures such as aircraft fuselages and train front cones, bogies, etc., housing, hotels, hospitals, bridges, among others.

[150] The innovative design of the tool allows the component to be Petition 870250102381, dated 07 / 11 / 2025, pp. 47 / 69 40 / 45 constructed in sections (if desired) and connected in an innovative manner, as explained in this patent application.

[151] overcoming many of the problems related to the transport of said large structures and / or components and their offshore installation, in the case of wind turbine blades (if installed offshore), eliminating the need for specialized maritime vessels used for the installation of turbine blades on generating mechanisms and the high costs associated with this process.

[152] The design of the tools also shows how large structures, such as housing, hospitals and warehouses, can be built quickly and shipped anywhere in the world; in the case of disaster areas, they can be built and shipped in a few hours, provided the tools are prefabricated. The tools can be manufactured and maintained for scenarios like these and can also be used to build low-cost housing wherever needed. This could overcome housing shortage problems in the UK, where there is a fundamental and growing need for fast and low-cost housing. A structure can be built and fitted out in a day, like a large production line, and then shipped or transported by road or air.If the height of the completed structures is too great to be transported by road, rail, or air, they can be produced near deep-water port docks and placed directly onto container ships.

[153] In addition to forming large structures, as can be seen in this patent, the design within this patent can also be used to create a mold and, with some modifications as described in this patent, enormous structures, such as coffins, can be produced rapidly, with greater structural integrity and longevity and at a lower cost than current production methods, which are time-consuming and slow due to the steel structural component of these structures, having to be produced at a high cost. A Petition 870250102381, dated 07 / 11 / 2025, pp. 48 / 69 41 / 45 Construction of these structures takes a long time, and as a result, projects are significantly delayed and can take years to complete, because without the structures in place, the remaining structure / surface that sits on the foundation formed by the caissons cannot be built upon, and this affects the construction of other structures, such as housing, warehouses, or airports, or indeed, seaports, on land reclaimed in most cases from the sea.

[154] Conclusion

[155] The description of the innovative mechanisms and systems above minimizes, if not eradicates, the real difficulties of manufacturing large structures and, if necessary, joining these large structures to form an even larger structure, such as a large wind turbine blade or aircraft fuselage or, indeed, rolling stock, such as the nose cone and bogies of a train, and habitable and working structures, such as dwellings, warehouses, hospitals and skyscrapers, but not limited to these.

[156] In joining large structures or components by means of sections, the difficulties lie in the structural integrity of the components at these junctions, where localized stress points may occur at the junction of these large structures or components (I mention large structures or components, but the principle shown in this patent applies to smaller structures or components). This is overcome by the fact that the design of the substructure within this patent is such that, when the sections are joined (connected), there are no localized stress points, due to the fact that there are large internal “superstructures” designed as a cross-section formed by the substructures, if necessary (or as a single horizontal substructure), which can run internally the entire length of the component, such as a large wind turbine blade, for example, thus eliminating any localized stress points.The overlapping of each of the vertical and horizontal substructures forms a superstructure internal to the one to which it is connected, as shown in this diagram. Petition 870250102381, dated 07 / 11 / 2025, pp. 49 / 69 42 / 45 patent, eliminates any localized stress points.

[157] The substructure or superstructure may have the length required, as required by the structural design; this structure, as mentioned above, eliminates any “localized” stress points and therefore the outer “sleeve / skin” or cover does not need to be a structural part of the entire component structure, serving only as an outer skin.

[158] As mentioned in this patent, the component is supported by the internal substructure of the cross-section and, moreover, this internal substructure is further structurally supported by the fact that one section can be placed inside the other, forming an internal superstructure that encompasses both parts of the tool. The amount of displacement of the length of the female section by the male section of the two structures will depend on the final structural integrity requirements of the structure or component and, therefore, the design of the component's structure and / or tool will take this into account.

[159] As mentioned in this patent, there may be a requirement for the final structure or component not to have a “vertical” structure and / or buttress above and / or below the horizontal structure and / or buttress, or only a vertical substructure or buttress, depending on the final structural and design requirements of the finished structure or component.

[160] The current methodology, especially in wind turbine blades, is to produce these structures as one large section.

[161] However, many issues arise regarding the production of these large structures, and these issues are well documented. To that end, we will cite only a few, such as: the considerable amount of labor hours required to produce these structures, for example, structures like wind turbine blades, where the process is, for the most part, labor-intensive, taking a significant amount of time, resulting in a substantial production cost, therefore comparable to an automated or semi-automated process, and not economically viable. Furthermore Petition 870250102381, dated 07 / 11 / 2025, pp. 50 / 69 43 / 45 of the above, the manual lamination process of the material that forms the composite structure may contain inaccuracies in the material deposition, resulting in localized stress points that can cause structural failures of the component. To further increase the difficulties in production, the internal superstructures have to be placed inside the blade as secondary processes and, in doing so, increase the cost of blade production and, once again, increase the possibilities of these structures failing due to the fact that they are secondary processes; if the internal structural components fail, then the entire component will fail.

[162] The issues above are just some of the many that need to be overcome in the design and production of large structures at a competitive cost in order to achieve market penetration and reduce the final selling price.

[163] For wind turbine blades (taking these structures as an example), there is also a substantial additional cost of transporting these large structures, which can be over 100 m long, and also of placing these structures on site, where there are only a few ocean-going vessels with the technology and capacity to perform such a task, again increasing the total cost of the blade.

[164] It is understood that much time, research and investment have been devoted to the development of the production of these large structures and that the expertise of the companies involved is world-leading. However, the processes are still mainly based on non-automated production systems and, as such, the cost, time and, indeed, the structural integrity of the components may result in very large structures that are not economically viable in the short, medium and long term.

[165] I believe that my patent overcomes many of the above issues by producing sections or large structures in a “single” process with respect to internal superstructures and external structures, where there are no secondary processes beyond the joining of the two halves of the tool, and this Petition 870250102381, dated 07 / 11 / 2025, pp. 51 / 69 44 / 45 can be made in a fully automated process using an external mechanism to join the two halves of the tool. To produce the components, the composite material must be wrapped around the tool halves, as shown in this patent, before joining the tool halves. Again, this can be done in a semi- or fully automated process, and there are several technologies that can accomplish this process and are currently on the market. I have mentioned the technology I prefer in this patent, but it is not limited to this technology, and therefore other viable technologies that are commercially available can very well be used, if necessary, to join the two halves of the tool to form the final structure or component.

[166] Furthermore, all thicknesses and structures of the materials can be designed to meet the structural requirements of the component and can be placed in situ by means of an automated process, as shown in this patent, thus eliminating issues related to the manual placement of the material to produce said structure or component, thus eliminating problems with the composite structure or inaccuracies in the deposition of the component material and e.

[167] Another major cost saving is that producing these components in sections 25 meters long or less facilitates transport, resulting in significant associated cost savings and additional savings with regard to placing these blades (if the final component is a blade for offshore wind power) on site, where specialized maritime vessels are no longer required.

[168] This type of structure can be extremely robust for joining two or more sections of large structures, such as wind turbine blades, aircraft fuselages, train nose cones, etc., but it is not limited to where the internal structure can act as a superstructure for any of the above structures and, moreover, manufactured in a single step.

[169] This process allows structures with high inherent strength Petition 870250102381, dated 07 / 11 / 2025, pp. 52 / 69 45 / 45 structures can be produced more efficiently and at a lower cost than known methods. This is especially advantageous in situations where the structure needs to be built quickly, such as in natural disaster situations (e.g., earthquakes, storms, floods, etc.), military scenarios, or, for example, during pandemics when medical buildings are needed in a short period of time.

[170] The methods and embodiments described herein are not limited to the implementations mentioned above. Modifications and additions may be made to the tool and methodologies, for example, by adding extra devices and steps to improve their specific usability. In particular, the invention and its embodiments may be usefully deployed or improved using the most advanced technology by means of material weaving and utilizing the advanced 3D weaving technology currently available, in which 3D weaving technology can combine various materials to provide ideal structural integrity with minimal cost related to material design. Petition 870250102381, dated 07 / 11 / 2025, pp. 53 / 69

Claims

1 / 8 CLAIMS 1. Tooling design enabling large structures or small structures or components to be produced in a possible single automated process (One Stop) characterized in that secondary processes are limited or reduced to a minimum or completely eradicated and where automated processes can be used in order to reduce the inaccuracies associated with manual production and, in turn, reduce the cost and time spent on said production where a tooling structure formed by means of two halves of said tooling structure and where these two individual tool halves are to be covered with suitable material, such as carbon fiber (by a suitable methodology), such as a 3D carbon fiber weave, but not limited to,which is in the form of a network (3D mesh) and fed into the tool by means of each individual half of the tool rotating on its central axis of rotation (if necessary) to be in synchronization with the input material fed by the weaving machine or tape winding machine, thus completely covering the tool section as needed and, when necessary, other methods may be deployed to cover the tool with the necessary material as needed to form the required final structure and / or component using buttresses that move within a set of flanges that are part of each half of the tool when brought together (by suitable automated or semi-automatic or manual means) form the final tool and the internal substructure,where the horizontal buttress overlaps the horizontal buttress of the opposite input tool and where the vertical buttresses of each tool enter the flanges of the corresponding tool, thus forming an internal superstructure by the buttresses and flanges of the tool, in the shape of a cross, whose length within the final structure or component depends purely on the structural requirements of the final structure and / or component and whose width is the width of the internal diameter of the tool and the final structure or component (where it needs to be the internal diameter), this Petition 870250080398, dated 08 / 09 / 2025, page 9 / 24 2 / 8 superstructure is designed to allow the strength, stiffness (in the case of turbine blades and aircraft structures as an example, but not limited to) and stability required for the entire final structure and / or component produced by the tool to form the body of the final structures or components and, furthermore,These internal structures can be designed within the final structure or component to extend beyond the parameters of the original structure or component so that these internal structures or superstructures can interconnect with a finished secondary structure or component in both the vertical and horizontal directions, so that multiple completed structures can be connected, if necessary, to form large structures such as wind turbine blades or aircraft fuselages or airframes, but not limited to these, and for example, coffin construction (as a form for concrete), civil construction, trains, aircraft structures and components, automotive parts and automotive body construction, but not limited to these, once the tooling has been removed by suitable means, leaving behind the final structure and / or component, such as the production of coffins.where the final structure formed by tooling will form the mold that shapes the caisson; it may be noted that, in some final structures or components, there may be a need for only one or more vertical buttresses or no vertical buttresses if the final design of the structure or component requires this to be the case and where structural integrity or otherwise permits more than one vertical buttress or even no vertical buttress.

2. Tooling design, according to claim 1, characterized in that the vertical buttresses of each section of the tool are offset relative to each other so as to allow two internal vertical buttresses to join together when entering the flanges of the respective sections of the tool, thus forming the final tool.

3. Tooling design, according to claim 1, characterized in that the final structures or components that are produced by the two independent tools are joined by suitable means to form a final structure and / or component by removing the tool (which is formed by joining the two individual halves of the tool), once the material has cured, if the material needs curing (the material, in this case, being carbon fiber the preferred material for this patent, but not limited to it), forming a structure and / or component.

4. Tooling design, according to claim 1, characterized in that the vertical buttresses (by which I mean the vertical buttress above and / or below the horizontal buttress) of the finished structure or component, these buttresses, whether vertical or horizontal, will be displaced against the vertical and / or horizontal buttresses of any completed secondary structure or component, so as to allow the internal vertical and / or horizontal buttresses of each finished structure or component when installed in another completed structure or component, thus allowing the buttresses of these structures or components to run parallel to each other, so as to allow these internal buttresses (of the two or more structures or components) to interconnect and thus join these secondary or multiple structures and / or components perfectly with suitable connections such as bolts or gluing.

5. Tooling design, according to claim 1, characterized in that the internal horizontal buttress and the internal vertical buttress of a completed structure or component interconnect with a second completed structure or component, meaning that the internal horizontal buttress and the internal vertical buttress can overlap to form a strong joint that can run the entire length (if necessary) of the two internal structures of the two independent structures and / or components; this internal structure, formed by the cross-section of the horizontal and vertical buttresses, is the internal superstructure that becomes an integral structural part of both structures or components that have been joined in this way.

6. Tooling design, according to claim 1, characterized by the fact that it also shows how the finished structure, with minor modifications, can be used as a mold for large structures, as described, except that the mold remains in situ, acting as an integral part of the structure, contributing to the strength and structural integrity of the structure created by the mold, thus creating large structures quickly and at low cost.

7. Tooling design, according to claim 1, characterized in that each horizontal buttress of the respective tool, where, when two halves of the tool are joined, they run parallel to each other, forming a hermetic fit so as to compress the material between the respective horizontal buttresses of each tool, once the sections of the tool are joined to form the final structure or component upon removal of the tool.

8. Tooling design, according to claim 1, characterized in that the internal structures or buttresses are coated with material, as are all surfaces of each individual tool (except where indicated, the individual tools shall not be coated); this material covering the buttresses forms the internal superstructure of the final structure and / or components, and this internal superstructure of the final structure or components is formed by removing the tool once the material has cured; if the material requires curing.

9. Tooling design, according to claim 1, characterized in that the combination of the two tool structures, when combined, also forms a horizontal internal buttress structure, the material forming this internal structure being twice the thickness of the material covering the vertical buttresses of the structure or component.

10. Tooling design, according to claim 1, characterized in that one of the flanges that forms part of the horizontal buttress in each tool is designed to move in a direction parallel to the other flange within this section of the tool, so as to compress the material covering the vertical buttress that enters between the flanges, forming the final structure or component produced by the tool.

11. Tooling design, according to claim 1, characterized in that if the final structure produced by the tool is that of an aircraft fuselage, for example, there will be a requirement for the horizontal buttress that will form the aircraft floor and a requirement for only one internal lower vertical buttress, the upper vertical buttress on the opposite surface of the horizontal buttress not being necessary, and this lower vertical buttress can be cut as needed to accommodate the internal requirements (without losing structural integrity) of the aircraft, such as electronic components, landing gear, cargo, but not limited to these.

12. Tooling design, according to claim 1, characterized in that the internal horizontal buttress structure of a completed structure or component can be interconnected with a second completed structure or component, meaning that the internal horizontal buttresses or structures can be overlapped where their corresponding surfaces form a hermetic fit, allowing a strong union of these surfaces that can run the entire length of the two internal structures, if necessary, and where the two horizontal structures can be joined and thus seamlessly joining the two structures or components by means of suitable connections such as screws or gluing.

13. Tooling design, according to claim 1, characterized in that the internal vertical buttress structure of a completed structure or component can be interconnected with a second completed structure or component, meaning that the internal buttresses can be overlapped where their corresponding surfaces form a hermetic fit, allowing a strong union of these surfaces that can run the entire length of the two internal structures, if necessary, and where also the two vertical buttress structures of each structure or component can be joined and thus joining the two structures or components perfectly by means of suitable connections such as screws or gluing.

14. Tooling design, according to claim 1, characterized in that to allow the vertical and horizontal support structures to overlap respectively the completed secondary structure or component, the tool is designed where the final structure or component formed by the tool accommodates an extension or lip of the horizontal and vertical buttresses to allow the creation of an overlap of the vertical and horizontal structures on the final structure or component.

15. Tooling design, according to claim 1, characterized in that there may be several internal vertical buttresses designed into the tool.

16. Tooling design, according to claim 1, characterized in that there may be only one horizontal buttress designed in the tool, but others may be incorporated into the final structure or component by means of partitions.

17. Tooling design, according to claim 1, characterized in that when each of the two halves of the tool is joined by suitable means, they form a complete tool which, once removed, will form the final structure or component.

18. Tooling design, according to claim 1, characterized in that the tool design incorporates a step, forming a male section so that a structure and / or component can fit inside a secondary structure or component, forming an enlarged fit between the two structures or components, the length or distance of a male section of the structure or component entering and passing through the female section of the other structure or component depends on the length of the male section and the required structural integrity of the joint.

19. Tooling design, according to claim 1, characterized in that the joining of two or more completed structures or components will be a smooth and seamless fit, so that the outer material or sleeve / skin will flow perfectly from one structure or component to the other, if an outer sleeve / skin is required.

20. Tooling design, according to claim 1, characterized in that the final structure or component may incorporate posts made of carbon fiber composite or suitable material to act as reinforcement for the concrete structure formed by the mold, for structures such as caissons, but not limited to that.

21. Tooling design, according to claim 1, characterized in that the structure for the mold may have, but is not limited to, a fabric that may be placed around the neck of the mold so that, when concrete is poured into the mold, when the mold is offshore and in situ, the concrete does not overflow into the sea or other water surfaces, but is not limited to that.

22. Tooling design, according to claim 20, characterized in that the structure or component can act as a mold for large structures, such as caissons, and, in doing so, carbon fiber posts / rods (for example) can be placed in the mold, forming a grid section that can act as structural reinforcement for the material (in this case, concrete).

23. Tooling design, according to claim 5, characterized in that the internal cross-section formed by both the horizontal and vertical buttresses, known as the superstructure (assuming there are two vertical buttresses, there may be, due to design requirements, only one vertical buttress or none) can run the entire length of the final internal structure and / or component and can extend beyond the limits of the main structure and component, if the design of the final structure or component so requires.

24. Tooling design, according to claim 16, characterized in that partitions can be placed within the final structure or component to increase the number of horizontal buttresses up to the full depth of said structure or component, crossing the vertical and horizontal buttresses. Petition 870250080398, dated 08 / 09 / 2025, page 15 / 24 8 / 8 to allow material to be poured into the final structure (in this case, concrete, but not limited to it), so that the partitions form a 3D honeycomb grid system, thus creating a substantial number of concrete columns, the number and dimensions of which will depend on the size of the final mold and the structural requirements of the large final structure.

25. Tooling design, according to claim 24, characterized in that partitions can be placed within the structure or end components; in this case, if they are large structures, such as houses, warehouses, hospitals and any other large structures, the partitions can be used to form rooms or separate small or large spaces, when necessary for human habitation, or otherwise.

26. Tooling design, according to claim 13, characterized in that multiple structures or components can be joined to form large structures, such as wind turbine blades, aircraft fuselages, boat hulls, but not limited to, in the case of building structures, where the structure or component can be joined both vertically and horizontally, or at degrees from the vertical or horizontal direction. Petition 870250080398, dated 08 / 09 / 2025, pp. 16 / 24

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