Moulding apparatus

Abstract

A moulding apparatus (1, 1') and associated method of moulding a tubular or hollow part. The apparatus includes a tool face component (10, 10'), induction coils (20, 21) around the tool face component and a support frame (30, 30') to which the tool face component and induction coils are mounted for supporting them during a moulding process. The tool face component describes a moulding surface (11, 11') circumscribing a moulding volume (12, 12'), which receives an inflatable bladder (13, 13') for urging moulding material against the moulding surface when it is heated to form a tubular or hollow moulding. The induction coils can heat the tool face component at a rate of at least 1.6 ºC / s.

Description

[0001] MOULDING APPARATUS

[0002] This invention relates generally to a moulding apparatus and an associated method of moulding. More specifically, although not exclusively, this invention relates to a moulding apparatus for making large composite parts.

[0003] Moulding composite materials having a thermoplastic or thermosetting matrix from preimpregnated plies requires the layered structure of plies to be cured and / or consolidated. This is generally carried out in an autoclave, a large enclosure in which the layered structure is heated and pressurised, which are required to provide a uniform temperature throughout the layered structure as it is cured and / or consolidated. Autoclaves are relatively expensive, particularly those which are configured for making large parts.

[0004] Resin transfer moulding is another known method of moulding composite materials. This method involves laying up plies of dry fibres, inserting them in a mould cavity, and injecting liquid resin under pressure into the mould cavity. Using resin transfer moulding, and similar moulding methods, to make large parts is also problematic due to the inherent difficulties in heating the mould cavity uniformly, among other issues.

[0005] One aim of this invention is to at least mitigate some of the issues with known composite moulding methods and equipment.

[0006] Accordingly, one aspect of the invention provides a moulding apparatus comprising a tool face component describing a moulding surface circumscribing a moulding volume, and a support frame to which the tool face component is mounted for supporting the tool face component, for example during a moulding process.

[0007] The provision of a tool face component supported by a support frame isolates the portion of the mould that needs to be heated. This reduces the time and energy required to heat and cool the moulding surface in the moulding process, when the moulding process involves heating and cooling of the moulding surface.

[0008] The tool face component, e.g. a moulding surface thereof, may be capable of being heated at a rate of at least 1.6 °C / s. In use, the tool face component or a moulding surface thereof may be heated at a lower or even higher rate, but it is preferably shaped and configured to at least be capable of being heated at a rate of at least 1.6°C. The tool face component may comprise a tubular tool face component.

[0009] The tool face component may be configured to receive, e.g. removably receive, in use, a bladder. The bladder may be for urging moulding material against the moulding surface, e.g. to form a moulding, for example a tubular or hollow moulding.

[0010] The moulding apparatus may comprise a bladder. The bladder may be removably receivable within the moulding volume, e.g. for urging moulding material against the moulding surface to form a moulding, for example a tubular or hollow moulding. The tool face component may comprise two or more parts. The two or more parts may be separable from one another, e.g. between a closed position and an open position. The two or more parts may be separable from one another from a closed position to an open position. In the closed position, the two or more parts may describe separate and / or opposed portions of the moulding surface. In the open position, the parts may be separated from one another, e.g. for facilitating removal of the bladder and / or moulding material or a moulded component from the moulding volume.

[0011] The separate and / or opposed portions of the moulding surface may be opposed to one another or comprise opposed portions of the moulding surface, e.g. such that the moulding volume is described between them. The tool face component may have a longitudinal axis. The two or more parts of the tool face component may describe portions of the moulding surface on opposite sides of the longitudinal axis.

[0012] Each part of the tool face component may describe a portion of the moulding surface on a respective side of the longitudinal axis. The parts of the tool face component may be separable in a direction substantially perpendicular to an axis, e.g. a longitudinal axis, of the tool face component. The parts of the tool face component may be separable by pivoting one part relative to another part, e.g. about an axis parallel to the axis of the tool face component.

[0013] Each part of the tool face component may be mounted to a respective support frame or part of the support frame. The parts of the support frame may be connected together, for example by hinges. The hinges may enable the two or more parts of the tool face component to be separable, for example by rotating one part of the support frame relative to another part of the support frame. The parts of the support frame may be securable together when the tool face component is in the closed position, for example using one or more latches or one or more releasable fasteners.

[0014] The tool face component may comprise alignment means. In the closed position, the parts of the tool face component may be aligned by the alignment means.

[0015] The alignment means may comprise a stepped profile or a tongue and groove or a lip. The alignment means may comprise alignment pins which are receivable in alignment apertures in either or both parts of the tool face component.

[0016] The tool face component, or at least one or each part of the tool face component, may, but need not, comprise two or more layers. The tool face component, or at least one or each part of the tool face component, may comprise a first layer. The first layer may provide or describes the moulding surface. The tool face component, or each part of the tool face component, may comprise a second layer. The second layer may be located on the opposite side of the first layer to the moulding surface.

[0017] The tool face component, or at least one or each part of the tool face component, may be susceptible to targeted heating or induction heated, e.g. by induction heating means. The tool face component, or at least one or each part of the tool face component, may comprise a ferromagnetic material, which may be susceptible to be induction heated, e.g. by induction heating means. The second layer may be susceptible to targeted heating or induction heating, e.g. by induction heating means. The second layer may be a ferromagnetic material, which may be susceptible to be induction heated, e.g. by induction heating means.

[0018] In some examples, the second layer may be susceptible to targeted heating, with the first layer being unheated, e.g. by the heating means.

[0019] The second layer may be additively manufactured, for example cold metal sprayed, onto the first layer. The first layer may be less than 5 mm thick, for example less than 4 mm thick, less than 3 mm thick, less than 2mm thick, less than 1 mm thick or less than 0.5 mm thick.

[0020] The first layer may be a pressed or rolled metal sheet or plate.

[0021] The first layer may have a thermal conductivity of at least 10 W / mK. Preferably, the first layer may have a thermal conductivity of at least 12 W / mK, more preferably at least 14 W / mK.

[0022] The first layer may be stainless steel or copper.

[0023] The tool face component, or at least one or each part of the tool face component, may, but need not, comprise one or more additional layers, for example a third and optionally fourth, fifth or more layers. At least one of the additional layers may be sandwiched between the first and second layer and / or configured to promote adhesion therebetween. At least one of the additional layers may comprise a coating or some other surface layer on the first layer, e.g. in which case the coating describes the moulding surface. The coating or other surface layer may comprise chrome, e.g. a hardened chrome face or surface. At least one of the additional layers may comprise graphene, which may be sandwiched between one or more of the other layers, or may describe an inner or outer surface.

[0024] The moulding apparatus may further comprise heating means. The heating means may be operable to heat the tool face component. The heating means may be operable to heat the tool face component without substantively heating the support frame. The heating means may be operable to heat the tool face component, e.g. a moulding surface thereof, at a rate of at least 1 .6 °C / s. The heating means may be operable to heat the tool face component, e.g. a moulding surface thereof, at a variable rate. In use, the heating means may heat the tool face component or a moulding surface thereof at a lower or even higher rate, but it is preferably capable of heating it at a rate of at least 1 ,6°C.

[0025] The moulding apparatus or heating means may comprise induction heating means. The induction heating means may be for induction heating the tool face component. The induction heating means may comprise one or more induction heating coils located in the support frame. In some examples, the heating means may be configured to provide targeted heating to the second layer, e.g. without heating the first layer. The first layer may be non-induction heatable or non-ferromagnetic or may not be induction heatable or ferromagnetic.

[0026] The support frame may comprise a plurality of plates. The plurality of plates may be spaced along a length, e.g. along a length direction, of the tool face component.

[0027] The support frame may comprise three or more spaced, substantially parallel support plates. The three of more support plates may be substantially perpendicular to the moulding surface. The three of more support plates may be substantially perpendicular to a longitudinal axis of the tool face component.

[0028] The moulding apparatus may comprise an air-inducing and / or air-cooling means. The airinducing and / or air-cooling means may be configured to induce an airflow between the plurality of plates. The air-inducing and / or air-cooling means may be configured to induce an airflow through the support frame. The air-inducing and / or air-cooling means may be configured to induce an airflow over one or more external surfaces of the tool face component. The air-inducing and / or air-cooling means may be configured to induce an airflow out of holes through at least some of the plates.

[0029] The air-cooling means may comprise a plurality of airflow inducing means, such as air cooling fans. The plurality of airflow inducing means may be configured to induce and / or direct and / or circulate airflow between the plurality of plates of the support frame.

[0030] The support frame may comprise or describe an air plenum, e.g. through and / or along which the air flows, in use, along the tool face component. The support frame may comprise or describe two or more air passages, channels or plenums, e.g. through and / or along which the air flows, in use, along the tool face component. The air passages, channels or plenums may be parallel to one another.

[0031] The moulding surface may comprise a tubular moulding surface. The moulding surface may comprise or describe a closed form. The tool face component may have a closed form cross-section. The volume of material forming the tool face component may be less than twice the moulding volume, for example less than 1.5 times, less than, less than 0.5 times or less than 0.25 times the moulding volume. The moulding apparatus may comprise connection means, for example axial connection means. The connection means may be located at one of its longitudinal ends, e.g. for connection with another similar moulding apparatus. The connection means may be for connection with another similar moulding apparatus, for example such that their moulding surfaces together describe a collective moulding surface. The collective moulding surface may circumscribe a collective moulding volume. The collective moulding volume may be configured to receive, e.g. removably receive, in use, a bladder. The bladder may be for urging moulding material against the collective moulding surface, such as to form a moulding, for example a tubular or hollow moulding.

[0032] According to another aspect of the invention there is provided a moulding system. The moulding system may comprise a plurality of the aforementioned moulding apparatus. The moulding system may comprise a bladder, which may be removably receivable within the collective moulding volume, e.g. for urging moulding material against the collective moulding surface to form a moulding, for example a tubular or hollow moulding.

[0033] According to another aspect of the invention there is provided a tool face component comprising first and second parts and alignment means, wherein the parts are separable from one another from a closed position, in which they are aligned by the alignment means such that they describe opposing portions of a moulding surface circumscribing a moulding volume, to an open position, in which the parts are separated from one another for facilitating removal of a bladder and / or moulding material or a moulded component from the moulding volume, the bladder being for urging moulding material against the moulding surface to form a moulding, for example a tubular or hollow moulding.

[0034] The alignment means may comprise a stepped profile. The stepped profile may be along a length of the first part. The stepped profile may be on either side of the moulding volume. The alignment means may comprise a stepped profile, which may be along a length of the second part and and / or on either side of the moulding volume. The stepped profiles of the first and second parts may cooperate with one another, for example when the first and second parts are in the closed position, thereby to align the moulding surfaces of the first and second parts. The tool face component may be for use in the aforementioned moulding apparatus or in each moulding apparatus of the aforementioned moulding system.

[0035] The tool face component may be free of cooling channels.

[0036] The moulding surface or collective moulding surface may comprise at least one dimension, e.g. a length, of at least or more than 1 m, preferably at least or more than 1 .5 m and more preferably at least 2m.

[0037] According to another aspect of the invention there is provided a method of moulding a part, for example a tubular or hollow part. The method may comprise placing moulding material between or within a moulding volume. The moulding volume may be described by a tool face component and a bladder received therein. The method may comprise heating the tool face component, e.g. a moulding surface thereof.

[0038] The tool face component may, but need not, be heated at a rate of at least 1.6 °C / s.

[0039] The method may comprise inflating the bladder, for example to urge the moulding material against the moulding surface of the tool face component that circumscribes the moulding volume. The method may comprise cooling the tool face component.

[0040] According to another aspect of the invention there is provided a method of moulding a part, for example a tubular or hollow part, the method comprising: placing moulding material between a moulding volume described by a tool face component and a bladder received therein; heating the tool face component, e.g. a moulding surface thereof, at a rate of at least 1.6 °C / s; inflating the bladder to urge the moulding material against the moulding surface of the tool face component that circumscribes the moulding volume; and cooling the tool face component.

[0041] The tool face component, or the moulding surface thereof, may be heated at a rate of at least 2 °C / s . Preferably, the tool face component, or the moulding surface thereof, is heated at a rate of at least 2.2 °C / s, more preferably at least 2.4 °C / s and most preferably at least 2.5 °C / s. In some examples, the tool face component, or the moulding surface thereof, is heated at a rate of at least 2.8 °C / s, for example at least 3 °C / s. The tool face component, or the moulding surface thereof, may be heated from a first temperature to a second temperature. The average heating rate from the first temperature to the second temperature may be at least 1.6 °C / s, preferably at least 2.2 °C / s, more preferably at least 2.4 °C / s, and most preferably at least 2.5 °C / s. In some examples, the average heating rate from the first temperature to the second temperature may be at least 2.8 °C / s, for example at least 3 °C / s.

[0042] Alternatively, the tool face component, or the moulding surface thereof, may be heated from the first temperature to the second temperature at two or more different heating rates. At least one of the two or more different heating rates may be at least 1 .6 °C / s, preferably at least 2.2 °C / s, more preferably at least 2.4 °C / s, and most preferably at least 2.5 °C / s. In some examples, at least one of the two or more different heating rates may be at least 2.8 °C / s, for example at least 3 °C / s.

[0043] The method may comprise induction heating the tool face component, or the moulding surface thereof.

[0044] The tool face component, or the moulding surface thereof, may be cooled at a rate of at least 0.1 °C / s. Preferably, the tool face component, or the moulding surface thereof, is cooled at a rate of at least 0.2 °C / s, more preferably at least 0.3 °C / s, and most preferably at least 0.5 °C / s.

[0045] The tool face component, or the moulding surface thereof, may be cooled from a third temperature to a fourth temperature. The third temperature may be or correspond substantively to the second temperature. The average cooling rate from the third temperature to the fourth temperature may be at least 0.1 °C / s, preferably at least 0.2 °C / s, more preferably at least 0.3 °C / s, and most preferably at least 0.5 °C / s.

[0046] Alternatively, the tool face component, or the moulding surface thereof, may be cooled from the third temperature to the fourth temperature at two or more different cooling rates. At least one of the two or more different cooling rates may be at least 0.1 °C / s, preferably at least 0.2 °C / s, more preferably at least 0.3 °C / s, and most preferably at least 0.5 °C / s.

[0047] The method may comprise circulating air over and / or across the tool face component, e.g. to cool the tool face component. The method may comprise circulating air across the tool face component within air passages. The air passages may be described by a plurality of plates, which may be spaced along a length direction of the tool face component. The plates may comprise part of a support frame, e.g. to which the tool face component may be mounted. At least some of the plates may comprise holes, e.g. through their thickness. The holes may form outlets of the air passages.

[0048] The tool face component may be mounted to a support frame. The support frame may comprise a plurality of plates, which may be spaced along a length direction of the tool face component. Air may be circulated over the tool face component within passages, channels or plenums described by the spaced plates.

[0049] The method may comprise separating first and second parts of the tool face component, for example after the tool face component has been cooled. The method may comprise removing the bladder from the separated parts of the tool face component.

[0050] Another aspect of the invention provides a moulding apparatus comprising a tool face component, for example a tubular tool face component, describing a moulding surface, which may circumscribe a moulding volume. The volume of material forming the tool face component may be less than twice the moulding volume.

[0051] The volume of material forming the tool face component may be less than 1.5 times the moulding volume. The volume of material forming the tool face component may be less than the moulding volume. The volume of material forming the tool face component may be less than 0.5 times the moulding volume. The volume of material forming the tool face component may be less than 0.25 times the moulding volume.

[0052] Preferably, the surface area of the moulding surface is at least ten times the minimum cross- sectional area of the tool face component, e.g. along a plane perpendicular to the moulding surface. More preferably, the surface area of the moulding surface is at least ten times the maximum cross-sectional area of the tool face component, e.g. along a plane perpendicular to the moulding surface.

[0053] Advantageously, the tool face component may have a relatively low thermal mass. This means that the tool face component might be heated and cooled relatively quickly. The moulding apparatus may comprise one or more, e.g. two or more, such as a plurality of, modules. Each module may comprise a portion of the tool face component. Each module may comprise a tool face portion, which may provide a portion of the tool face component. Each module may comprise a portion of the heating means or a heating means portion. Each module may comprise heating means, e.g. for heating the tool face portion. Each module may comprise a portion of the support frame or a support frame portion, e.g. for supporting the tool face portion. The modules may be secured or securable together, e.g. such that the tool face portions together provide the tool face component describing a moulding surface.

[0054] Another aspect of the invention provides a moulding apparatus comprising two or more modules each comprising a tool face portion, heating means for heating the tool face portion and a support frame portion for supporting the tool face portion, wherein the modules are secured or securable together such that the tool face portions together provide a tool face component describing a moulding surface.

[0055] In some examples each module comprises a respective bladder. In other examples, the moulding apparatus comprises a single bladder, which may be configured to be received in the assembled modules or a composite moulding volume described by the assembled tool face portions of the modules.

[0056] The support frame or each support frame portion may comprise a plurality of, e.g. three or more, substantially planar support members. The support frame or each support frame portion or the support members may comprise a plurality of, e.g. three or more, support plates or sheets. The support members or plates or sheets may be spaced from one another and / or parallel to one another. The support members or plates or sheets may be substantially perpendicular to the moulding surface and / or may support the tool face component.

[0057] The support members or plates or sheets may be spaced along a length of the tool face component. The support members or plates or sheets may be orientated such that the tool face component extends through apertures or channels in the support plates, such that the tool face component is supported in a radial direction by the support plates. The support frame or each support frame portion may comprise a pair of substantially planar side members. The support frame or each support frame portion or support members may comprise side plates. The side members or plates may be perpendicular to the support members or plates and / or may each be at one end of the support members or plates. An enclosure, e.g. a support enclosure, may be described by the side members or plates and the outermost support members or plates.

[0058] Advantageously, this design may make a modular mould design possible. Furthermore, this design may enable uniform cooling by circulating air around the tool face component or portion, due to relatively low contact area between the support members or plates or sheets and the tool face component or portion. This may remove or reduce the complexity of cooling the tool face component or portion.

[0059] The tool face component may be split into two or more parts or portions along the axial direction thereof. Each module may comprise one of the parts or portions. A first part or portion of the tool face component may be supported by a first set of the plurality of support members or plates or sheets, e.g. a first module may comprise the first set. A second part or portion of the tool face component may be supported by a second set of the plurality of support members or plates or sheets, e.g. a second module may comprise the second set.

[0060] The first and second sets of support members or plates or sheets may be securable together. The first and second modules or sets of support members or plates or sheets may be securable together, e.g. such that the first and second parts or portions of the tool face component provide the moulding volume.

[0061] The moulding apparatus or each module may comprise a fluid flow or airflow inducing means for inducing a flow of fluid, for example air, along the tool face portion or component, e.g. on the opposite side thereof to the moulding surface.

[0062] Another aspect of the invention provides a moulding apparatus comprising a tool face component describing a moulding surface, a heating means for heating the tool face component, a support frame for supporting the tool face component and airflow inducing means for inducing a flow of air along the tool face component on the opposite side thereof to the moulding surface. The airflow inducing means may comprise one or more air circulating fans. The airflow means may be configured to circulate cooling air over an external surface of the tool face component.

[0063] The moulding apparatus or support frame or each module or each support frame portion may comprise or describe an air plenum, e.g. through and / or along which the air flows, in use, along the tool face component. The moulding apparatus or support frame or each module or each support frame portion may comprise or describe two or more air passages, channels or plenums, e.g. through and / or along which the air flows, in use, along the tool face component. The air passages, channels or plenums may be parallel to one another. The modules may be configured to connect the air passages, channels or plenum(s) of each module to one another.

[0064] The heating means may comprise one or more induction coils. The tool face component or tool face portion may be susceptible to be induction heated, for example by electromagnetic induction from the induction coils. The tool face component or tool face portion may be at least partially magnetic, e.g., at least a part of the tool face component may be substantially magnetic. Part of the tool face component may be substantially non-magnetic.

[0065] An outer surface of a cross-section the tool face component, at all positions along a length of the moulding volume, may be substantially polygonal, for example rectangular, pentagonal, hexagonal or octagonal. The polygonal shape may be a regular or an irregular polygonal shape. The polygonal shape may have at least four, for example at least five, six or eight, lines of symmetry.

[0066] An outer surface of a cross-section of the tool face component, at one or more or all positions along a length of the moulding volume, may be substantially elliptical or circular in shape. At least a portion of an outer surface of a cross-section of the tool face component may be non-uniform or comprise a complex or irregular geometry or curvature.

[0067] A wall thickness of the tool face component may be substantially uniform or non-uniform around the perimeter of the moulding volume at all positions along a length of the moulding volume. The cross-section of the moulding surface at one or more or all positions along a length of the moulding volume of the tool face component may be substantially circular in shape. At least a portion of the cross-section of the moulding surface of the tool face component may be non-uniform or comprise a complex or irregular geometry or curvature.

[0068] The cross-section of the moulding surface at all positions along a length of the moulding volume of any of the tool face component, may be substantially central in the cross-section of the tool face component.

[0069] The tool face component may comprise a sheet or a plate.

[0070] The tool face component may comprise a first layer which provides the moulding surface. The tool face component may comprise a second layer, which may be located on the opposite side of the first layer to the moulding surface. The second layer may be substantially magnetic. The second layer may be susceptible to be induction heated, e.g. by the or a plurality of induction coils comprised in the heating means.

[0071] Another aspect of the invention provides a moulding apparatus comprising: a tool face component, for example a tubular tool face component, for use in a moulding apparatus, the tool face component describing a moulding surface circumscribing a moulding volume; heating means for heating the tool face component; and a bladder receivable within the moulding volume for urging moulding material against the moulding surface to form a moulding, for example a tubular or hollow moulding; wherein the tool face component comprises a first layer, which provides the moulding surface, and a second layer, located on the opposite side of the first layer to the moulding surface, wherein the second layer is substantially magnetic and is configured to be induction heated.

[0072] The first layer may be substantially non-magnetic. The second layer may be additively manufactured, for example cold metal sprayed, onto the first layer. The first layer may be a pressed or rolled metal sheet or plate.

[0073] Another aspect of the invention provides a method of manufacturing a tool face component, for example a tubular tool face component, the method comprising rolling or pressing a metal sheet to form a first part of the tool face component, the first part of the tool face component describing a moulding surface, for example with a closed-form cross-section, circumscribing a moulding volume, the method comprising additively manufacturing, for example cold metal spraying, a magnetic material onto a surface of the first part of the tool face component which is on the opposite side of the first part to the moulding surface.

[0074] Another aspect of the invention provides a method of forming a moulding, for example a tubular or hollow moulding, the method comprising: locating moulding material inside of the moulding volume of any of the aforementioned moulding apparatus; locating a bladder inside of the moulding material; inflating the bladder to urge the moulding material against the moulding surface; heating the tool face component to form the moulding from the moulding material.

[0075] Heating the tool face component may comprise induction heating the tool face component.

[0076] The method may comprise circulating air over the tool face component to cool the tool face component. The method may comprise circulating air over the tool face component to cool the tool face component after the tool face component has been heated.

[0077] The moulding material may be a fibre reinforced thermoplastic material, for example a braided fibre thermoplastic matrix composite material.

[0078] Heating the tool face component may cause the thermoplastic in the fibre reinforced thermoplastic material to melt, and subsequent cooling of the tool face component may cause the thermoplastic material to solidify to produce the moulding, for example a tubular or hollow moulding.

[0079] The method may comprise opening the tool face component about an or the axial split therein, to locate the moulding material and the bladder inside of the tool face component. The method may comprise closing the tool face component to define the moulding volume with the moulding material and bladder therein.

[0080] Another aspect of the invention provides a tool face component, for example a tubular tool face component, describing a moulding surface, for example with a closed-form crosssection, circumscribing a moulding volume, wherein the volume of material forming the tool face component is less than twice the moulding volume. The tool face component may be for bladder moulding a tubular structure, such that a bladder is receivable within the moulding volume for urging moulding material against the moulding surface to form a tubular moulding.

[0081] The moulding material which is used or is usable in any of the aforementioned moulding apparatus, tool components, or methods, may be a fibre reinforced thermoplastic material, for example a braided fibre thermoplastic matrix composite material.

[0082] For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, any of the moulding apparatus or tool face components may comprise any one or more features of any of the other moulding apparatus and / or tool face components. Also, any of the methods may comprise any one or more features or steps relevant to one or more features of any of the moulding apparatus and / or tool face components.

[0083] Another aspect of the invention provides a computer program element comprising and / or describing and / or defining a three-dimensional design, e.g. of any of the aforementioned moulding apparatus or any of the aforementioned tool face components or embodiments thereof. The three-dimensional design may be for use with a simulation means or an additive or subtractive manufacturing means, system or device.

[0084] The computer program element may be for causing, or operable or configured to cause, an additive or subtractive manufacturing means, system or device to manufacture any part of the moulding apparatus or the tool face component described above or an embodiment thereof. The computer program element may comprise computer readable program code means for causing an additive or subtractive manufacturing means, system or device to execute a procedure to manufacture any part of the aforementioned moulding apparatus or the aforementioned tool face components or embodiments thereof.

[0085] A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the aforementioned method.

[0086] A yet further aspect of the invention provides the computer program element embodied on a computer readable medium. A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method.

[0087] A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium.

[0088] For purposes of this disclosure, and notwithstanding the above, it is to be understood that any controller(s), control units and / or control modules described herein may each comprise a control unit or computational device having one or more electronic processors. The controller may comprise a single control unit or electronic controller or alternatively different functions of the control of the system or apparatus may be embodied in, or hosted in, different control units or controllers or control modules. As used herein, the terms “control unit” and “controller” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause said controller(s) or control unit(s) or control module(s) to implement the control techniques described herein (including the method(s) described herein). The set of instructions may be embedded in one or more electronic processors, or alternatively, may be provided as software to be executed by one or more electronic processor(s).

[0089] For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present invention is not intended to be limited to any particular arrangement. In any event, the set of instructions described herein may be embedded in a computer-readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors / computational device, including, without limitation: a magnetic storage medium (e.g., floppy diskette); optical storage medium (e.g., CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information / instructions. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and / or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.

[0090] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

[0091] Figure 1 is a schematic of a first embodiment of a moulding apparatus according to the invention;

[0092] Figure 2 is a cross-section of a tool face component of the moulding apparatus of Figure 1 , together with a deflated bladder for insertion therein;

[0093] Figure 3 is a schematic of a support sheet of the moulding apparatus of Figure 1 ;

[0094] Figure 4 is a schematic of a second embodiment of a moulding apparatus according to the invention;

[0095] Figure 5 is an end view of the moulding apparatus of Figure 4;

[0096] Figure 6 is a cross-section of a tool face component of the moulding apparatus of Figures 4 and 5, together with a deflated bladder for insertion therein; Figure 7 is a graph showing the temperature profile of the tool face component of the moulding apparatus of Figures 4 to 6 during a first example moulding cycle; and

[0097] Figure 8 is a graph showing the temperature profile of the tool face component of the moulding apparatus of Figures 4 to 6 during a second example moulding cycle.

[0098] Referring now to Figure 1 , there is shown a part of a moulding apparatus 1 . The moulding apparatus 1 has two, side-by-side, tool face components 10, only one of which is shown in Figure 1. In this example the tool face components 10 are tubular in shape. The moulding apparatus 1 also has induction heating means 20 associated with each tool face component 10, the induction heating means 20 surrounding the respective tool face component 10, with only induction heating means 20 surround a half of one tool face components 10 being shown in Figure 1. The moulding apparatus 1 also has a support frame 30 in which the tool face components 10 and the heating means 20 are mounted for supporting the tool face components 10 during moulding processes.

[0099] Each tool face component 10 is split in half, axially, and only a first part 10a of one of the tool face components 10 is shown in Figure 1. Each tool face component 10 describes a moulding surface 11 circumscribing a moulding volume 12. The tool face component 10 is made of a magnetic material, e.g., steel, and so is susceptible to be induction heated by electromagnetic induction from the induction heating means 20.

[0100] Each of the induction heating means 20 has a plurality of induction coil tubes 21 which are in a spaced arranged and which surround the circumference of each tool face component 10. The induction coil tubes 21 extend along a length direction of the respective tool face component 10. In this example, each tool face component 10 is surrounded by eight induction coil tubes 21. Only four, out of eight, of the induction coil tubes 21 , surrounding one of the tubular tool face components 10, are shown in Figure 1. The induction coil tubes 21 contain induction heating coils (not shown).

[0101] The support frame 30 has a plurality of spaced apart support plates 31 for supporting the tool face components 10 and the heating coils 21 , which are described in more detail subsequently, with reference to Figure 3. The support frame 30 has an end plate 32 at either end thereof and has side plates 33 extending along the sides thereof, along the length direction of the tool face components 10. The end sheets 32 have extensions at either end thereof, to provide legs 32a. The side plates 33 have extensions at either end thereof, to provide legs 33a. When the support frame 30 is assembled, edges of adjacent legs 32a, 33a of the end plates 32 and side plates 33 abut one another to provide corner legs for the moulding apparatus 1. Each side plate 33 also has an extension at the centre in the length direction, to provide a central leg 33b.

[0102] The end plates 32 have fixing holes 32b extending therethrough, to secure ends of the tool face components 10 to the end plates 32 using fasteners.

[0103] The support frame 30 has a central support plate 34 which is parallel to the side plates 32 and extends between the tool face components 10. All of the plates of the support frame 30, in this example, are produced using mild steel. However, it will be appreciated that any suitable material may be used, for example aluminium.

[0104] The moulding apparatus has a second half, which is similar to the first half shown in Figure 1 . The second half of the moulding apparatus 1 has the second parts 10b of the tool face components 10 and is securable atop the first half of the moulding apparatus 1 of Figure 1 , such that the moulding surface 11 of each tool face component 10 has a closed-form crosssection.

[0105] The moulding apparatus 1 also has bladders 13 which are locatable in the moulding volume of each tool face component 10. The moulding apparatus 1 also has air circulating fans (not shown) which are configured to circulate air between the plates 31 , 32, 33, 34 of the support frame 30, such that the air passes over, and cools, the tool face components 10.

[0106] It will be appreciated that the moulding apparatus 1 may be of any length, with any number of support plates 31. Furthermore, any number of tool face components 10 may be provided, for example 1 , 3 or 4, or any other number.

[0107] Referring now to Figure 2, there is shown a cross-section through a centre point along the length of one of the tool face components 10 of the moulding apparatus 1. The first and second parts 10a, 10b of the tool face component 10 are shown in a closed configuration, such that the moulding surface 11 has a closed-form cross-section. Also illustrated is a deflated bladder 13 for insertion into the moulding volume 12. In this example the tool face component 10 has an irregular octagonal outer cross-sectional shape. The octagonal shape has horizontal and vertical sides which are substantially equal in length, and has four shorter diagonal sides. The octagonal shape has four lines of symmetry. However, it will be appreciated that other polygonal shapes, such as rectangular, pentagonal or hexagonal, or elliptical shapes, such as circular, are envisaged. In this example the moulding volume 12 is circular in cross-sectional shape and is centrally located in the tool face component 10, to improve the uniformity of heating and cooling of the moulding material. It will be appreciated, however, that other cross-sectional shapes of moulding volume 12 are envisaged, for example oval shapes.

[0108] The ratio of the cross-sectional area of the material forming the tool face component 10 is around 1.4 times the cross-sectional area of the moulding volume. Also, the ratio of the volume of the material forming the tool face component 10 is around 1.4 times the moulding volume. This ratio is low compared to tool face components known in the art, and advantageously, means that the tool face component 10 has a low thermal mass, and so can be heated and cooled relatively quickly and / or with relatively low power. Furthermore, by supporting the tool face component 10 in a support frame 30, the tool face component 10 can be heated without substantively heating the support frame 30.

[0109] Each part 10a, 10b of the tool face component 10 has alignment means in the form of a stepped profile 10aa along a length of the first part and on either side of the moulding volume 12 and a stepped profile 10ba along a length of the second part 10b and on either side of the moulding volume 12. The stepped profiles 10aa, 10ba of the first and second parts 10a, 10b cooperate with one another when the first and second parts 10a, 10b are in a closed position, thereby aligning the moulding surfaces 11 of the first and second parts 10a, 10b.

[0110] Referring now to Figure 3 one of the support plates 31 is shown. The support plates 31 have two tool face component channels 311 extending from an upper edge thereof, each tool face component channel 311 being shaped to receive one of the tool face components 10. Extending from each tool face component channel 311 are four coil tube channels 312, each coil tube channel being for receiving an induction coil tube 21 therein. Extending out of the plane of the support plate 31 are four securement tabs 313, two of the securement tabs 313 extending from an edge of one of the tool face component channels 311 and the other two securement tabs 313 extending from an edge of the other tool face component channel 311. Each securement tab 313 has a fastener hole extending therethrough. The securement tabs 313 are configured to abut the diagonal surfaces of the tool face components 10 when the tool face components 10 are located in the tool face component channels 311.

[0111] The support plate 31 has an interlocking groove 314 extending from a lower surface thereof, which is configured to engage with an interlocking groove (not shown) on the central support plate 34 of the support frame 30. The support plate 31 has interlocking shoulders 315 extending from either side thereof, which are configured to engage with interlocking grooves extending from upper surfaces of the side support plates 33 of the support frame 30.

[0112] The assembly of the moulding apparatus 1 is now described, and this description is the same for each half of the moulding apparatus 1 . One of the induction coil tubes 21 is placed inside of each coil tube channel 312 in each support plate 31 . The induction coils are either present before the induction coil tubes 21 are installed into the support frame 30, or are inserted afterwards.

[0113] Each part 10a, 10b of each tool face component 10 is installed in the respective tool face component channel 311 in the support plates 31 and secured thereto using fasteners which extend through the holes in the securement tabs 313. Each part 10a, 10b of each tool face component is secured to the end plates 32 using fasteners, as described previously.

[0114] The interlocking shoulders 315 of the support plates 31 are engaged with the interlocking grooves on the side support plates 33. The interlocking groove 314 of each support plate 31 is engaged with the interlocking grooves of the central support plate 34 and the interlocking groove of each end plate 32 is engaged with ends of the central support plate 34. The plates 31 , 32, 33, 34 of the support frame 30 may be welded together or secured together using fasteners (not shown).

[0115] Advantageously, this construction of the support frame 30 enables large moulding apparatus to be produced in an efficient manner, as a plurality of side support plates 33 can be attached together along the length, and additional support plates 31 can be provided between the end plates 32, to increase the size of the moulding apparatus 1 , and the number of tool face component channels 311 , and the width of the support plates 31 can be changed to change the number of tool face components 10 which can be providing in the moulding apparatus 1.

[0116] It will be appreciated that whilst the moulding apparatus 1 is illustrated with four induction coils 21 associated with each half 10a, 10b of each tool face component 10, any number of induction coils 21 can be provided, to suit the size and heating requirements of the tool face component 10. It will also be appreciated that the spacing of the support plates 31 , shown in Figure 1 , is for illustration only, and the actual spacing, as well as the number of support plates 31 , will dependent upon the size and moulding requirements of the tool face components 10.

[0117] In use, the two halves of the moulding apparatus 1 are separated and moulding material, for example fibre reinforced thermoplastic material, is placed in the moulding volumes 12. The bladders are placed in the moulding volumes 12 such that the moulding material is between the respective bladder and the respective moulding surface. The two halves of the moulding apparatus are then secured together such that the moulding volumes 12 are closed around the moulding material and bladders. The tool face components 10 are then heated via induction heating from the induction coils 21 , and the bladders are inflated to urge the moulding material against the respective moulding surface 11.

[0118] In certain moulding processes it is appropriate to inflate the bladder during heating, in some moulding processes it is appropriate to inflate the bladder before heating, and in some moulding processes it is appropriate to heat the tool face component before inflating the bladder. Thermoplastic in the moulding material is thereby melted, or a chemical reaction in thermosetting plastic in the moulding material is initiated, and the moulding material is compressed, to form a tubular or hollow structure (not shown). The plastic material is cured by stopping induction heating and circulating air over the tool face component 10 to cool the tool face component 10. The bladders are then deflated and the two halves of the moulding apparatus 1 are separated to release the tubular structures from the respective moulding volumes 11. The deflated bladders are removed from the tubular structures.

[0119] Referring now to Figures 4 and 5, a moulding apparatus T according to a second embodiment of the invention is shown. The moulding apparatus T of this embodiment is similar to the moulding apparatus 1 of the previous embodiment, and similar features are denoted with the same reference numerals, with a succeeding prime (‘). The moulding apparatus T of this embodiment includes two modules M1 , M2 secured together at their ends. More specifically, one end plate 32’ of the first module M1 is bolted to an end plate 32’ of the second module M2. Cooling fans 40’ of the second module M2 are also shown in this embodiment, which are mounted to the underside of the support frame 30’ and direct air upwardly, into the support frame 30’. Air flow passages are formed between the plates 3T, 32’, 33’, 34’ and through a plurality of holes 35’ which extend through the support plates 3T, 34’ and the side plates 33’. The cooling fans 40’ induce an airflow through the flow passages, across the tool face component 10’ and out through the holes 35’ of the plates 3T, 33’, 34’.

[0120] Each module M1 , M2 of the moulding apparatus T of Figures 4 and 5 has a tubular tool face component 10’, heating means 20’ and a support frame 30’, as in the previous embodiment. Whilst each module M1 , M2 of the moulding apparatus T only of this example only has one tool face component 10’, any number of adjacent tool face components 10’ can be provided side-by-side, as explained with reference to the embodiment of Figure 1. If multiple tool face components 10’ are provided in the moulding apparatus T of this embodiment, then the support frame 30’ is widened to accommodate these tool face components 10’ in a similar manner to that illustrated in the previous embodiment in Figure 1. Also, the heating means 20’ of this embodiment has 16 induction coil tubes 2T (only eight of which are shown in Figure 4) surrounding the tool face component 10’, but it will be appreciated that any number can be provided, depending upon the size of the tool face components and the induction heating power requirements thereof.

[0121] Also, as per the previous embodiment of Figure 1 , the moulding apparatus T is split into two halves such that the tool face component 10’ is split axially into a first part 10a’ and a second part 10b’, and the second part 10b’ of the second module M2 is shown in Figures 4 and 5. As in the previous embodiment, the two halves of the moulding apparatus T are securable together to form the moulding volume 12’ of the tool face component, with a closed-form cross-sectional moulding surface 1 T circumscribing the moulding volume 12’.

[0122] In this embodiment each end plate 32’ has a tool face component channel, as do the support plates 3T. Each end plate 32’ also has induction coil tube channels 322’, as do the support plates 3T. In this way, the end plates 32’ of this embodiment are similar to the support plates 3T, with the exception that the end plates 32’ have legs 32a’. This enables a modular construction of the support frame 30’ such that the moulding apparatus T can be extended to the desired length by securing modules M1 , M2 together, each with their respective tool face component 10’ or by providing a single tool face component 10’ that passes through the tool face component channel in the end plate 32’.

[0123] The moulding apparatus T has axial connection means in the form of an elongate fastener 32c’ passing through the fixing holes 32b’ of each end plate, such that the tool face components 10’ of the modules M1 , M2 together describe a collective moulding surface circumscribing a collective moulding volume. Blank end plates (not shown), similar to those in the previous embodiment, may be provided at either end of the moulding apparatus T, if desired.

[0124] Referring now to Figure 6, an end view of the tool face component 10’ is shown. The tool face component 10’ of this embodiment has a first layer 10T and a second layer 102’. The first layer 10T provides the moulding surface 1 T. Also illustrated is a deflated bladder 13’ for insertion into the moulding volume 12’.

[0125] The first layer 10T preferably has a thermal conductivity of at least 10 W / mK and is formed from a pressed or rolled metal plate. The first layer 10T preferable has a thickness of between 1 mm and 10 mm. The first layer 10T is preferably made from a material which provides beneficial strength and moulding properties, such as stainless steel. However, any suitable material may be used. Advantageously, the first layer 10T is relatively simple to manufacture, compared to cutting the moulding volume 12’ from a billet of material, whilst providing a smooth surface finish and acceptable tolerances. Also, as the first layer 10T is produced from metal plate, it is relatively lightweight to handle, making manufacturing and assembly of the moulding apparatus T easier.

[0126] The second layer 102’ is magnetic and is preferably cold metal sprayed onto the opposite side of the first layer 10T to the moulding surface 1 T. In this way, the second layer 102’ is susceptible to be induction heated by the induction heating coils 2T. Cold metal spraying the second layer 102’ makes manufacture of the tool face component 10’ easier, as the first layer 10T can be assembled in the support frame 30’ to provide the moulding surface 1 T before the remainder of the tool face component 10’, namely the second layer 102’, is installed. As shown in Figure 6, the alignment means of this embodiment is provided by stepped profiles 10aa’, 10ba’ on the first and second parts 10a’, 10b’ of the tool face component 10’, as in the previous embodiment. However, the stepped profile 10aa’ is provided by the first layer 10T extending further, circumferentially, on the first part 10a’ of the tool face component 10’ than the second layer 102’. Inversely, on the second part 10b’ of the tool face component 10’, the second layer 102’ extends further, circumferentially, than the first layer 10T, to provide the stepped profile 10ba’. As in the previous embodiment, the stepped profile aligns the moulding surfaces 1 T of the first and second parts 10a’, 10b’ when the tool face component 10’ is closed.

[0127] As shown in Figure 6, the wall thickness of the tool face component 10’ is substantially unform around the circumference thereof. Also, as shown in Figures 4 and 5, the wall thickness of the tool face component 10’ is substantially uniform around the perimeter of the moulding volume 12’ at all positions along a length of the moulding volume 12’.

[0128] The ratio of the cross-sectional area of the moulding volume 12’ to the cross-sectional area of material forming the tool face component 10’, in this embodiment, is 0.22. The crosssection of the moulding volume 12’ and of the tool face component 10’ is consistent along the length of the tool face component 10’, meaning that the ratio of the moulding volume 12’ to the material forming the tool face component 10’ is also 0.22. However, even if the cross-sectional shape of the tool face component 10’ changes along the length of the moulding volume 12’, the ratio of moulding volume to material forming the tool face component is still able to be maintained below 1 , preferably below 0.5 and even more preferably below 0.25. This means that the tool face component 10’ has a low thermal mass and so can be heated and cooled quickly. Furthermore, by supporting the tool face component 10’ in a support frame 30’, the tool face component 10’ can be heated without substantively heating the support frame 30’.

[0129] Moulding operations using the moulding apparatus T of Figures 4 to 6 are similar to those using the moulding apparatus 1 of the previous embodiment. Namely the two halves of the moulding apparatus T are separated and moulding material, preferably fibre reinforced thermoplastic material, is placed in the moulding volume 12’ of the tool face component 10’. A bladder is placed in the moulding volume 12’ such that the moulding material is between the bladder and the moulding surface 1 T. The two halves of the moulding apparatus T are then secured together, for example using latches (not shown) on the two parts of the support frame 30’, such that the moulding volume 12’ is closed around the moulding material and the bladder. The second layer 102’ of the tool face component 10’ is then heated via induction heating from the induction coils 2T, and this heat conducts through the first layer 10T to the moulding material.

[0130] Preferably, the first layer 10T is not induction heated, but is merely heated due to conduction from the second layer 102’. The bladder is inflated to urge the moulding material against the moulding surface 1 T provided by the first layer 10T. In certain moulding processes it is appropriate to inflate the bladder during heating, in some moulding processes it is appropriate to inflate the bladder before heating, and in some moulding processes it is appropriate to heat the tool face component before inflating the bladder. Thermoplastic in the moulding material is thereby melted, or a chemical reaction in thermosetting plastic in the moulding material is initiated, and the moulding material is compressed, to form a tubular structure (not shown). The plastic material is cured by stopping induction heating and circulating air over the tool face component 10’ to cool the tool face component 10’. The bladder is then deflated and the two halves of the moulding apparatus T are separated to release the tubular structure from the moulding volume 1 T. The deflated bladder is removed from the tubular structure.

[0131] Figure 7 illustrates the temperature profile of the tool face component 10’ of the moulding apparatus T during a moulding cycle according to a first example, in which the cooling portion of the moulding cycle is carried out without the use of the cooling fans 40’. The average heating rate during this moulding cycle is approximately 2.8 °C / s, while the average cooling rate is approximately 0.2 °C / s. It will be appreciated that the maximum temperature, approximately 240 °C in this example, and the time during which the tool face component 10’ is at this maximum temperature are illustrated purely by way of example. The actual maximum moulding temperature and time will depend upon the characteristics of the part to be moulded.

[0132] Figure 8 illustrates the temperature profile of the tool face component 10’ of the moulding apparatus T during a moulding cycle according to a second example, in which the cooling portion of the moulding cycle is carried out with the cooling fans. The tool face component 10’ is also heated at a higher rate by applying more power to the induction heating coils 2T. The average heating rate during this moulding cycle is approximately 4.6 °C / s, while the average cooling rate is approximately 0.33 °C / s. It is envisaged that the cooling rate may be increased further, either by increasing the volume flow rate of the fans 40’ or by cooling the temperature of the air introduced by the fans.

[0133] It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, as mentioned throughout the description of both embodiments, any number of tool face components of any length and size can be produced by extending the support frame and changing the size of the tool face component or components, accordingly. Another variation may be that the induction coil tubes and induction coils are omitted an the tool face component is heated via another heating means, for example using conduction or convention heaters located around the tool face components.

[0134] It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and / or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

CLAIMS1. A method of moulding a tubular or hollow part, the method comprising: placing a polymeric composite material between a moulding volume described by a tool face component and a bladder received therein; induction heating the tool face component at a rate of at least 1.6 °C / s; inflating the bladder to urge the moulding material against a moulding surface of the tool face component that circumscribes the moulding volume; and cooling the tool face component at a rate of at least 0.2°C / s.

2. A method according to claim 1 comprising circulating air across the tool face component within air passages described by a plurality of plates spaced along a length direction of the tool face component, wherein the plates comprise part of a support frame to which the tool face component is mounted.

3. A method according to claim 2, wherein at least some of the plates comprise holes through their thickness which form outlets of the air passages.

4. A method according to claim 2 or claim 3, wherein the tool face component is free of cooling channels.

5. A method according to claim 1, wherein the tool face component is heated at a rate of at least 2.5 °C / s.

6. A method according to any preceding claim, wherein the tool face component is cooled at a rate of at least 0.3 °C / s.

7. A method according to any preceding claim comprising separating first and second parts of the tool face component after the tool face component has been cooled and removing the bladder from the separated parts of the tool face component.

8. A moulding apparatus for carrying out a method according to any preceding claim, the apparatus comprising a tool face component describing a moulding surface circumscribing a moulding volume and a support frame to which the tool face component is mounted for supporting the tool face component during a mouldingprocess, wherein the tool face component is configured to removably receive, in use, a bladder for urging moulding material against the moulding surface to form a tubular or hollow moulding.

9. A moulding apparatus according to claim 8 comprising a bladder removably receivable within the moulding volume for urging moulding material against the moulding surface to form a tubular or hollow moulding, wherein the tool face component comprises two or more parts which are separable from one another from a closed position, in which they describe opposed portions of the moulding surface, to an open position, in which the parts are separated from one another for facilitating removal of the bladder from the moulding volume.

10. A moulding apparatus according to claim 9, wherein each part of the tool face component is mounted to a respective support frame or part of the support frame.

11. A moulding apparatus according to claim 9 or claim 10, wherein the tool face component comprises alignment means, and wherein, in the closed position, the parts of the tool face component are aligned by the alignment means.

12. A moulding apparatus according to any one of claims 8 to 11 , wherein the tool face component comprises a first layer, which provides or describes the moulding surface, and a second layer, located on the opposite side of the first layer to the moulding surface.

13. A moulding apparatus according to claim 12, wherein the second layer is a ferromagnetic material susceptible to be induction heated by induction heating means.

14. A moulding apparatus according to claim 12 or claim 13, wherein the second layer is additively manufactured, for example cold metal sprayed, onto the first layer.

15. A moulding apparatus according to any of claims 12 to 14, wherein the first layer is less than 2mm thick.

16. A moulding apparatus according to any of claims 12 to 15, wherein the first layer is a pressed or rolled metal sheet or plate.

17. A moulding apparatus according to any of claims 12 to 16, wherein the first layer has a thermal conductivity of at least 10 W / mK.

18. A moulding apparatus according to any one of claims 8 to 17, further comprising induction heating means for induction heating the tool face component.

19. A moulding apparatus according to any one of claims 8 to 18, wherein the support frame comprises a plurality of plates which are spaced along a length of the tool face component.

20. A moulding apparatus according to any one of claim 19, comprising an air-inducing means which is configured to induce an airflow between the plurality of plates, through the support frame, over one or more external surfaces of the tool face component and out of holes through at least some of the plates.

21. A moulding apparatus according to any one of claims 8 to 20 comprising axial connection means located at one of its longitudinal ends for connection with another similar moulding apparatus, such that their moulding surfaces together describe a collective moulding surface circumscribing a collective moulding volume configured to removably receive, in use, a bladder for urging moulding material against the collective moulding surface to form a tubular or hollow moulding.

22. A moulding system comprising a plurality of moulding apparatus according to claim 21 and a bladder removably receivable within the collective moulding volume for urging moulding material against the collective moulding surface to form a tubular or hollow moulding.

23. A moulding apparatus according to any one of claims 8 to 21 or a moulding system according to claim 22, wherein the moulding surface or collective moulding surface comprises a length of more than 1 .5 m.

24. A tool face component for use in a moulding apparatus according to any one of claims 8 to 21 , the tool face component comprising first and second parts and alignment means, wherein the parts are separable from one another from a closed position, in which they are aligned by the alignment means such that they describe opposing portions of the moulding surface, to an open position, in which the parts are separated from one another for facilitating removal of the bladder from the moulding volume.

25. A tool face component according to claim 23, wherein the alignment means comprise a stepped profile along a length of the first part and on either side of the moulding volume, and a stepped profile along a length of the second part and on either side of the moulding volume, wherein the stepped profiles of the first and second parts cooperate with one another when the first and second parts are in the closed position, thereby to align the moulding surfaces of the first and second parts.

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