Tooling sets, systems and methods for stamp forming workpiece

Abstract

To provide a tooling set, a system and a method in which the pressure applied to a workpiece during stamp forming is uniform.SOLUTION: A tooling set for stamp forming a workpiece (102) includes a first stamping tool (104), a second stamping tool (110) and an elastomeric layer (114) between the first and second stamping tools (104, 110). The first stamping tool (104) defines a first forming face (108). The second stamping tool (110) defines a second forming face (112). The elastomeric layer (114) defines first and second compliant stamping surfaces (116, 118). A method includes positioning a workpiece (102) between the first stamping tool (104) and the elastomeric layer (114) and compressing the workpiece between the first forming face (108) and the first compliant stamping surface (116) in response to the first and second stamping tools (104, 110) being approximated.SELECTED DRAWING: Figure 20

Description

[Technical field]

[0001] The present disclosure relates generally to stamp forming a workpiece, and more particularly to using a tooling set with an elastomeric layer for stamp forming a workpiece. The tooling set may include, for example, opposing stamping dies configured to accommodate at least one elastomeric layer that deforms upon compression of the workpiece. The elastomeric layer balances pressure on the workpiece caused by compression between the forming surfaces of the stamping dies. It is contemplated that the same elastomeric layer may be used in different stamping dies having different forming surfaces. Also, a variety of materials are contemplated for the elastomeric layers and workpieces. [Background technology]

[0002] While current stamping of workpieces (e.g., parts) revolves around the use of matching die sets, several issues arise associated with the use of such die sets when scaling up to larger part sizes. Material thickness variations combined with tool manufacturing tolerances often result in uneven pressure distribution on the part surface. Such pressure variations can create a manufacturing environment that promotes poor material consolidation and associated voids, with significant adverse effects on part performance. This is typically resolved by increasing the stamping pressure. However, increasing the pressure can result in excessive part thickness reduction and is not practical for large products. To improve the quality of large parts and increase productivity, a flexible and adaptable forming surface is desirable. Boeing currently manufactures one side of their stamp form die (SFD) tools using an elastomeric material to achieve a more uniform surface pressure. However, such elastomeric inserts quickly degrade due to the harsh thermal and mechanical environment during part consolidation. Typical inserts last for less than 10 stamping cycles and are limited to certain part geometries. Furthermore, replacing elastomeric inserts is expensive and time consuming.

[0003] Accordingly, those skilled in the art continue to conduct research and development efforts to improve the design of stamping dies, particularly those using elastomeric materials. Summary of the Invention

[0004] Disclosed are examples of die sets, systems, and methods for stamping a workpiece. The following are non-exhaustive examples of subject matter according to the present disclosure, and may include those embodiments that are either claimed or not claimed.

[0005] In one embodiment, the disclosed method for stamping a workpiece includes: (1) positioning the workpiece between a first stamping die and an elastomeric layer opposing the first stamping die, the elastomeric layer being disposed between the first stamping die and a second stamping die, the first stamping die defining a first molding surface and the second stamping die defining a second molding surface opposing the first molding surface, the elastomeric layer defining a first compliant stamping surface opposing the first molding surface and a second compliant stamping surface opposing the second molding surface; and (2) compressing the workpiece between the first molding surface and the first compliant stamping surface by bringing the first stamping die and the second stamping die closer together.

[0006] In another embodiment, a method of the present disclosure for stamping a workpiece includes: (1) positioning the workpiece between a first stamping die and a second stamping die, the first stamping die defining a first molding surface and the second stamping die defining a second molding surface opposite the first molding surface; (2) positioning an elastomeric layer between the first stamping die and the workpiece, the elastomeric layer defining a first compliant stamping surface opposite the first molding surface and a second compliant stamping surface opposite the second molding surface and facing the workpiece; and (3) compressing the workpiece between the second compliant stamping surface and the second molding surface by bringing the first stamping die and the second stamping die closer together.

[0007] In one embodiment, a mold set of the present disclosure for stamping a workpiece includes a first stamping die, a second stamping die, and an elastomeric layer. The first stamping die has a given thickness and defines a first molding surface. The second stamping die has a given thickness and defines a second molding surface opposite the first molding surface. The elastomeric layer has a given thickness and is disposed between the first stamping die and the second stamping die. The elastomeric layer defines a first compliant stamping surface opposite the first molding surface and a second compliant stamping surface opposite the second molding surface.

[0008] In one embodiment, a system of the present disclosure for stamping a workpiece includes a mold set including a first stamping die, a second stamping die, and an elastomeric layer. The first stamping die has a given thickness and defines a first molding surface. The second stamping die has a given thickness and defines a second molding surface opposite the first molding surface. The elastomeric layer has a given thickness and is disposed between the first stamping die and the second stamping die. The elastomeric layer defines a first compliant stamping surface opposite the first molding surface and a second compliant stamping surface opposite the second molding surface.

[0009] Other embodiments of the die sets, systems, and methods for stamping a workpiece according to the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the appended claims. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a cross-sectional view of an example of a mold set for stamping a workpiece. [Diagram 2] 1 is a flow chart of an example method for stamping a workpiece. [Diagram 3] 2, is a flow chart illustrating another example of a method for stamping a workpiece. [Figure 4] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Diagram 5] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 6] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 7] 2, is a flow chart illustrating another example of a method for stamping a workpiece. [Figure 8] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 9] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 10] 2 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 11] 4 is a flow chart of another example of a method for stamping a workpiece. [Figure 12] 11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 13] 11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 14] 11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 15] 11 is a flow chart illustrating another example of a method for stamping a workpiece. [Figure 16]11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 17] 11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 18] 11 is a flow chart illustrating yet another example of a method for stamping a workpiece. [Figure 19] 11 is a flow chart illustrating another example of a method for stamping a workpiece. [Figure 20] 1 is an exploded functional diagram of an example system for stamping a workpiece; [Figure 21] FIG. 2 is an exploded functional diagram of another example of a system for stamping a workpiece. [Figure 22] 1 is a functional cross-sectional view of an example of a workpiece between a molding surface and a compliant stamping surface in a mold set for stamping the workpiece; FIG. [Diagram 23] 1 is a functional cross-sectional view of an example workpiece between another molding surface and a compliant stamping surface in another mold set for stamping the workpiece. FIG. [Figure 24] FIG. 1 is a block diagram of an aircraft production and service method. [Diagram 25] FIG. 1 is a schematic diagram of an aircraft. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] With reference generally to Figures 1-10, 20, and 21, by way of example, the present disclosure relates to methods 200, 300, 400, 500, 600, 700, 800, 900, 1000 for stamping a workpiece 102. Optional features in Figures 2-10 are indicated by dashed blocks in the flow charts. Figure 2 discloses some example methods 200. Figures 3-10, in combination with Figure 2, disclose other example methods 300, 400, 500, 600, 700, 800, 900, 1000.

[0012] 1 and 2, in one or more examples, a method 200 (see FIG. 2) for stamping a workpiece 102 begins at step 202 with positioning the workpiece 102 between a first stamping die 104 and an elastomeric layer 114 facing the first stamping die 104. The elastomeric layer 114 is disposed between the first stamping die 104 and a second stamping die 110. The first stamping die 104 defines a first molding surface 108. The second stamping die 110 defines a second molding surface 112 facing the first molding surface 108. The elastomeric layer 114 defines a first compliant stamping surface 116 facing the first molding surface 108 and a second compliant stamping surface 118 facing the second molding surface 112. In step 204 , the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 between the first molding surface 108 and the first compliant stamping surface 116 .

[0013] In another example of the method 200, the elastomeric layer 114 includes an elastomeric sheet. In a further example, the elastomeric sheet has a uniform thickness. In yet another example, the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0014] In yet another example of method 200 , elastomeric layer 114 is removably secured to second stamping die 110 .

[0015] In yet another example, the method 200 also includes a step 206 of positioning the elastomeric layer 114 between the first stamping die 104 and the second stamping die 110. After step 206, the method 200 begins at step 202.

[0016] In yet another example, upon reaching a predetermined pressure during compression step 204, method 200 proceeds from step 204 to step 208, where the first compliant stamping surface 116 of elastomeric layer 114 is deformed based on the first geometry of first molding surface 108, and the second compliant stamping surface 118 of elastomeric layer 114 is deformed based on the second geometry of second molding surface 112, in step 210. Workpiece 102 is deformed based on the first geometry of first molding surface 108, the deformed first compliant stamping surface 116, the deformed second compliant stamping surface 118, and the second geometry of second molding surface 112, in step 212. In a further example, the predetermined pressure is about 400 psi or greater, about 300 psi or greater, about 200 psi or greater, about 100 psi or greater, or any other suitable minimum compression pressure. In yet another example, the first shape of the first molding surface 108 includes a flat portion, a contour portion, a protrusion, a ramping portion, a descending portion, a step portion, a convex portion, or any other suitable shape portion in any suitable combination. In yet another example, the second shape of the second molding surface 112 matches the first shape of the first molding surface 108.

[0017] 1-3, in one or more examples, a method 300 (see FIG. 3) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. In one example, the method 300 includes a step 302 of preheating the workpiece 102 to at least a predetermined melting point of the thermoplastic matrix material. From step 302, the method 300 proceeds to step 202 of the method 200. In a further example, the predetermined melting point is between about 300° C. and about 500° C., between about 300° C. and about 400° C., between about 300° C. and about 360° C., or any other suitable melting point range associated with the thermoplastic matrix material.

[0018] 1-3, in another example, the method 300 also includes step 304 of preheating the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 to a predetermined solidification temperature of the thermoplastic matrix material. From step 304, the method 300 proceeds to step 202 of the method 200 (see FIG. 2) described above. In a further example, the predetermined solidification temperature is between about 150° C. and about 300° C., between about 200° C. and about 300° C., between about 250° C. and about 300° C., or any other suitable solidification temperature range associated with the thermoplastic matrix material.

[0019] 1, 2, and 4, in one or more examples, a method 400 (see FIG. 4) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. From step 204 of method 200, method 400 proceeds to step 402, which includes consolidating the workpiece 102 in response to reaching a predetermined pressure during compression step 204. In a further example, the predetermined pressure is about 400 psi or more, about 300 psi or more, about 200 psi or more, about 100 psi or more, or any other suitable minimum consolidation pressure.

[0020] 1, 2, and 5, in one or more examples, a method 500 (see FIG. 5) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. Method 500 proceeds from step 204 of method 200 to step 502, in which the first stamping die 104 and the second stamping die 110 are separated to release the workpiece 102. Then, in step 504, the workpiece 102 is removed from between the first molding surface 108 and the first compliant stamping surface 116.

[0021] 1, 2, and 20, in one or more examples, one method for stamping the workpiece 102 includes the method 200 (see FIG. 2) described above. The method continues from step 202 of the method 200 by positioning a second elastomeric layer 2002 between the elastomeric layer 114 and the workpiece 102 in a direction along the stamping axis 106. The second elastomeric layer 2002 defines a third compliant stamping surface 2004 opposite the first compliant stamping surface 116 and a fourth compliant stamping surface 2006 facing the workpiece 102 and opposite the second molding surface 112. The method then proceeds to step 204 of the method 200. In a further example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the first stamping die 104. In yet another example, second elastomeric layer 2002 has different properties than elastomeric layer 114 .

[0022] 1, 2, 6, and 20, in one or more examples, a method 600 (see FIG. 6) for stamping a workpiece 102 includes method 200 (see FIG. 2) described above. Method 600 proceeds from step 202 of method 200 to step 602, in which a second elastomeric layer 2002 is positioned between the first stamping die 104 and the workpiece 102 in an orientation along the stamping axis 106. The second elastomeric layer 2002 defines a third compliant stamping surface 2004 facing the first molding surface 108 and a fourth compliant stamping surface 2006 facing the workpiece 102 and facing the second molding surface 112. Method 600 then proceeds to step 204 of method 200. In a further example, the second elastomeric layer 2002 is removably secured to the first stamping die 104 .

[0023] 1, 2, 7, and 20, in one or more examples, a method 700 (see FIG. 7) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. Method 700 proceeds from step 204 of method 200 to step 702, in which a third compliant stamping surface 2004 of second elastomeric layer 2002 is deformed based on the first shape of first molding surface 108 in response to reaching a predetermined pressure during compression step 204. Then, in step 704, a second compliant stamping surface 118 of elastomeric layer 114 is deformed based on the second shape of second molding surface 112. Then, in step 706, the workpiece 102 is deformed based on the first shape of the first molding surface 108, the deformed third compliant stamping surface 2004, the deformed second compliant stamping surface 118, and the second shape of the second molding surface 112.

[0024] 1, 2, 8, and 20, in one or more examples, a method 800 (see FIG. 8) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. In one example, the method 800 includes a step 802 of preheating the workpiece 102 to at least a predetermined melting point of the thermoplastic matrix material. From step 802, the method 800 proceeds to step 202 of the method 200.

[0025] 1, 2, 8, and 20, method 800 also includes step 804 of preheating first stamping mold 104, second stamping mold 110, elastomeric layer 114, and second elastomeric layer 2002 to a predetermined solidification temperature of the thermoplastic matrix material. From step 804, method 800 proceeds to step 202 of method 200.

[0026] 1, 2, and 9, in one or more examples, a method 900 (see FIG. 9) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. From step 204 of method 200, method 900 proceeds to step 902, which includes consolidating the workpiece 102 in response to reaching a predetermined pressure during compression step 204.

[0027] 1, 2, 10, and 20, in one or more examples, a method 1000 (see FIG. 10) for stamping a workpiece 102 includes the method 200 (see FIG. 2) described above. From step 204 of method 200, method 1000 proceeds to step 1002, in which the first stamping die 104 and the second stamping die 110 are separated to release the workpiece 102. Then, at step 1004, the second elastomeric layer 2002 and the workpiece 102 are removed from between the second molding surface 112 and the first compliant stamping surface 116. Then, at step 1006, the workpiece 102 is removed from the fourth compliant stamping surface 2006 of the second elastomeric layer 2002.

[0028] With reference to Figures 1, 11-19, 20, and 21, by way of example, the present disclosure relates to methods 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, and 1900 for stamping a workpiece 102. Optional features in Figures 11-19 are indicated by dashed blocks in the flow charts. Figure 11 discloses some example methods 1100. Figures 12-19, in combination with Figure 11, disclose other example methods 1200, 1300, 1400, 1500, 1600, 1700, 1800, and 1900.

[0029] 1 and 11, in one or more examples, a method 1100 (see FIG. 11) for stamping a workpiece 102 begins at step 1102 with positioning the workpiece 102 between a first stamping die 104 and a second stamping die 110. The first stamping die 104 defines a first molding surface 108. The second stamping die 110 defines a second molding surface 112 opposite the first molding surface 108. At step 1104, an elastomeric layer 114 is positioned between the first stamping die 104 and the workpiece 102. The elastomeric layer 114 defines a first compliant stamping surface 116 opposite the first molding surface 108 and a second compliant stamping surface 118 opposite the second molding surface 112 and facing the workpiece 102. In step 1106 , the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 between the second compliant stamping surface 118 and the second molding surface 112 .

[0030] In another example of the method 1100, the elastomeric layer 114 includes an elastomeric sheet. In a further example, the elastomeric sheet has a uniform thickness. In yet another example, the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0031] In yet another example of the method 1100 , the elastomeric layer 114 is removably secured to the first stamping die 104 .

[0032] In another example, upon reaching a predetermined pressure during compressing step 1106, the method 1100 proceeds from step 1106 to step 1108, in which the first compliant stamping surface 116 of the elastomeric layer 114 is deformed based on the first shape of the first molding surface 108, and the second compliant stamping surface 118 of the elastomeric layer 114 is deformed based on the second shape of the second molding surface 112, in step 1110, and the workpiece 102 is deformed based on the first shape of the first molding surface 108, the deformed first compliant stamping surface 116, the deformed second compliant stamping surface 118, and the second shape of the second molding surface 112, in step 1112.

[0033] 1, 11, and 12, in one or more examples, a method 1200 (see FIG. 12) for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. In one example, the method 1200 includes a step 1202 of preheating the workpiece 102 to at least a predetermined melting point of the thermoplastic matrix material. From step 1202, the method 1200 proceeds to step 1102 of the method 1100.

[0034] 1, 11, and 12, in another example, method 1200 also includes step 1204 of preheating first stamping die 104, second stamping die 110, and elastomeric layer 114 to a predetermined solidification temperature of the thermoplastic matrix material. From step 1204, method 1200 proceeds to step 1102 of method 1100 (FIG. 11) described above.

[0035] 1, 11, and 13, in one or more examples, a method 1300 (see FIG. 13) for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. Method 1300 proceeds from step 1106 of method 1100 to step 1302, which includes consolidating the workpiece 102 in response to reaching a predetermined pressure during compression step 1106.

[0036] 1, 11, and 14, in one or more examples, a method 1400 (see FIG. 14) for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. Method 1400 proceeds from step 1106 of method 1100 to step 1402, in which the first stamping die 104 and the second stamping die 110 are separated to release the workpiece 102, and the elastomeric layer 114 and workpiece 102 are then removed from the second molding surface 112, and the workpiece 102 is then removed from the second compliant stamping surface of the elastomeric layer 114, in step 1406.

[0037] 1, 11, and 21, in one or more examples, one method for stamping the workpiece 102 includes the method 1100 (see FIG. 11) described above. The method continues from step 1106 of the method 1100 by positioning a second elastomeric layer 2002 between the workpiece 102 and the second stamping die 110 in an orientation along the stamping axis 106. The second elastomeric layer 2002 defines a third compliant stamping surface 2004 facing the workpiece 102 and opposite the first molding surface 108, and a fourth compliant stamping surface 2006 facing the second molding surface 112 of the second stamping die 110. In a further example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the second stamping die 110. In yet another example, second elastomeric layer 2002 has different properties than elastomeric layer 114 .

[0038] 1, 11, 15, and 21, in one or more examples, a method 1500 for stamping a workpiece 102 includes method 1100 (see FIG. 11) described above. Method 1500 proceeds from step 1102 of method 1100 to step 1502, in which a second elastomeric layer 2002 is positioned between the workpiece 102 and the second stamping die 110 in an orientation along the stamping axis 106. The second elastomeric layer 2002 defines a third compliant stamping surface 2004 facing the workpiece 102 and opposite the first molding surface 108, and a fourth compliant stamping surface 2006 opposite the second molding surface 112. Method 1500 then proceeds to step 204 of method 200. In a further example, the second elastomeric layer 2002 is removably secured to the second stamping die 110 .

[0039] 1, 11, 16, and 21, in one or more examples, a method 1600 for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. From step 1106 of method 1100, method 1600 proceeds to step 1602, in which, in response to reaching a predetermined pressure during compression step 1106, a second compliant stamping surface 118 of elastomeric layer 114 is deformed based on the first shape of first molding surface 108. Then, in step 1604, a third compliant stamping surface 2004 of second elastomeric layer 2002 is deformed based on the second shape of second molding surface 112. Then, in step 1606, the workpiece 102 is deformed based on the first shape of the first molding surface 108, the deformed second compliant stamping surface 118, the deformed third compliant stamping surface 2004, and the second shape of the second molding surface 112.

[0040] 1, 11, 17, and 21, in one or more examples, a method 1700 for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. In one example, the method 1700 includes a step 1702 of preheating the workpiece 102 to at least a predetermined melting point of the thermoplastic matrix material. From step 1702, the method 1700 proceeds to step 1102 of the method 1100.

[0041] 1, 11, 17, and 21, method 1700 also includes step 1704 of preheating first stamping mold 104, second stamping mold 110, elastomeric layer 114, and second elastomeric layer 2002 to a predetermined solidification temperature of the thermoplastic matrix material. From step 1704, method 1700 proceeds to step 1102 of method 1100.

[0042] 1, 11, 18, and 21, in one or more examples, a method 1800 for stamping a workpiece 102 includes method 1100 (see FIG. 11) described above. In this example, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. From step 1106 of method 1100, method 1800 proceeds to step 1802, which includes consolidating the workpiece 102 in response to reaching a predetermined pressure during compression step 1106.

[0043] 1, 11, 19, and 21, in one or more examples, a method 1900 for stamping a workpiece 102 includes the method 1100 (see FIG. 11) described above. From step 1106 of method 1100, method 1900 proceeds to step 1902, in which the first stamping die 104 and the second stamping die 110 are separated to release the workpiece 102, and at step 1904, the workpiece 102 and the second elastomeric layer 2002 are removed from the second molding surface 112. At step 1906, the workpiece 102 is removed from the third compliant stamping surface of the second elastomeric layer 2002.

[0044] Referring generally to FIGS. 1 and 20-23, by way of example, the present disclosure relates to a die set 100 for stamping a workpiece 102. FIG. 1 discloses an example of a die set 100, including a first stamping die 104, a second stamping die 110, and an elastomeric layer 114. FIGS. 20 and 21 disclose an example of a system 2008 for stamping a workpiece 102, including a die set 2000. FIG. 22 discloses an example die set 100' in which a workpiece 102' is positioned between a first stamping die 104' and an elastomeric layer 114. FIG. 23 discloses an example die set 100" in which a workpiece 102" is positioned between a first stamping die 104" and an elastomeric layer 114.

[0045] 1, 20, and 21, in one or more examples, a mold set 100 for stamping a workpiece 102 includes a first stamping die 104, a second stamping die 110, and an elastomeric layer 114. The first stamping die 104 has a given thickness and defines a first molding surface 108. The second stamping die 110 has a given thickness and defines a second molding surface 112 opposite the first molding surface 108. The elastomeric layer 114 has a given thickness and is disposed between the first stamping die 104 and the second stamping die 110. The elastomeric layer 114 defines a first compliant stamping surface 116 opposite the first molding surface 108 and a second compliant stamping surface 118 opposite the second molding surface 112.

[0046] In another example of mold set 100, elastomeric layer 114 includes an elastomeric sheet. In a further example, the elastomeric sheet has a uniform thickness. In yet another example, the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0047] In yet another example of the mold set 100, the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 are configured to position the workpiece 102 between the first molding surface 108 of the first stamping die 104 and the first compliant stamping surface 116 of the elastomeric layer 114. In a further example, the elastomeric layer 114 is removably secured to the second stamping die 110. In yet another example, the elastomeric layer 114 is configured to conform to the first molding surface 108 of the first stamping die 104 upon engagement of the first molding surface 108 with the workpiece 102, engagement of the workpiece 102 with the first compliant stamping surface 116 of the elastomeric layer 114, and engagement of the second compliant stamping surface 118 of the elastomeric layer 114 with the second molding surface 112 of the second stamping die 110.

[0048] In yet another example of the mold set 100, the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 are configured to position the workpiece 102 between the second molding surface 112 of the second stamping die 110 and the second compliant stamping surface 118 of the elastomeric layer 114. In a further example, the elastomeric layer 114 is removably secured to the first stamping die 104. In yet another example, the elastomeric layer 114 is configured to conform to the second molding surface 112 of the second stamping die upon engagement of the second molding surface 112 with the workpiece 102, engagement of the workpiece 102 with the second compliant stamping surface 118 of the elastomeric layer 114, and engagement of the first compliant stamping surface 116 of the elastomeric layer 114 with the first molding surface 108 of the second stamping die 110.

[0049] In yet another example of mold set 100, elastomeric layer 114 is replaceable.

[0050] In another example of mold set 100, elastomeric layer 114 comprises silicone rubber, neoprene rubber, fluoroelastomer rubber, fiber reinforced rubber, particle reinforced rubber, nitrile rubber, butadiene rubber, urethane rubber, rubber-like material, ethylene propylene diene monomer (EPDM) rubber, foam rubber, sponge rubber, styrene butadiene rubber, or any other suitable elastomeric material in any suitable combination.

[0051] In yet another example of mold set 100, the minimum thickness of elastomeric layer 114 is about 1 / 32 inch, about 1 / 16 inch, about 1 / 8 inch, about 3 / 16 inch, about 3 / 32 inch, about 1 / 4 inch, about 3 / 8 inch, about 1 / 2 inch, about 3 / 4 inch, about 1 inch, about 1.5 inches, about 2 inches, or any other suitable minimum thickness. In yet another example of mold set 100, the length of elastomeric layer 114 is about 0.25 feet to about 200 feet, 0.5 feet to about 100 feet, about 1 foot to about 50 feet, about 2 feet to about 25 feet, about 4 feet to about 12.5 feet, or any other suitable range of lengths. In yet other examples of mold set 100, elastomeric layer 114 has a height ranging from about 3 inches to about 144 inches, from about 6 inches to about 72 inches, from about 12 inches to about 36 inches, or any other suitable range of heights.

[0052] In another example of the mold set 100, the thickness of the elastomeric layer 114 is based, at least in part, on the tolerances of the stamping surfaces of the first stamping die 104 and the second stamping die 110. In yet another example of the mold set 100, the thickness of the elastomeric layer 114 is based, at least in part, on the thickness variation of the workpiece 102 and / or the thickness tolerance of the workpiece 102.

[0053] In yet another example of the mold set 100, the elastomeric layer 114 is configured to deform from an area of ​​high pressure to an area of ​​low pressure when the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 and the elastomeric layer 114. In a further example, the deformation of the elastomeric layer 114 balances the pressure on the workpiece 102 when the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 and the elastomeric layer 114.

[0054] In yet another example of mold set 100, elastomeric layer 114 has a stiffness of about 0.1 MPa to about 500 MPa, about 0.5 MPa to about 250 MPa, about 1 MPa to about 50 MPa, about 2 MPa to about 25 MPa, about 4 MPa to about 12.5 MPa, or any other suitable range of stiffness. In another example of mold set 100, elastomeric layer 114 has a stiffness that is less than the stiffness of workpiece 102 when the thermoplastic matrix material of workpiece 102 turns into a solid at the solidification temperature.

[0055] In yet another example of the mold set 100, the elastomeric layer 114 is configured for use at a maximum temperature of about 350° C., about 325° C., about 300° C., about 275° C., about 250° C., about 225° C., about 200° C., about 175° C., about 150° C., or any other suitable maximum temperature. In yet another example of the mold set 100, the elastomeric layer 114 is configured for use with other mold sets 100 with different stamping dies 104, 110 having different molding surfaces 108, 112.

[0056] In yet another example of die set 100 , first molding surface 108 , second molding surface 112 , first compliant stamping surface 116 , and second compliant stamping surface 118 extend outwardly from stamping axis 106 .

[0057] In another example of the mold set 100, the first stamping die 104 and the second stamping die 110 are matching dies. In yet another example of the mold set 100, the first stamping die 104 and the second stamping die 110 comprise elemental metals, metal alloys, or any other suitable materials in any suitable combination.

[0058] In yet another example of mold set 100, workpiece 102 is a thermoplastic composite that includes reinforcing fibers embedded in a thermoplastic matrix material.

[0059] In yet another example, the mold set 100 also includes a second elastomeric layer 2002 having a thickness along the stamping axis 106 and disposed between the first stamping die 104 and the second stamping die 110 adjacent the elastomeric layer 114. The second elastomeric layer 2002 defines a third compliant stamping surface 2004 opposing the first molding surface 108 of the first stamping die 104 and a fourth compliant stamping surface 2006 opposing the second molding surface 112 of the second stamping die 110.

[0060] In a further example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the second compliant stamping surface 118 of the elastomeric layer 114 and the third compliant stamping surface 2004 of the second elastomeric layer 2002. In yet another example, the elastomeric layer 114 is removably secured to the first stamping die 104 and the second elastomeric layer 2002 is removably secured to the second stamping die 110.

[0061] In a further example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the fourth compliant stamping surface 2006 of the second elastomeric layer 2002 and the second molding surface 112 of the second stamping die 110. In a further example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the first stamping die 104.

[0062] In yet another example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the first compliant stamping surface 116 of the elastomeric layer 114 and the fourth compliant stamping surface 2006 of the second elastomeric layer 2002.

[0063] In yet another example, elastomeric layer 114 is removably secured to second stamping die 110 and second elastomeric layer 2002 is removably secured to first stamping die 104 .

[0064] In yet another example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the first molding surface 108 of the first stamping die 104 and the third compliant stamping surface 2004 of the second elastomeric layer 2002. In yet another example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the second stamping die 110.

[0065] In yet another example, second elastomeric layer 2002 has different properties than elastomeric layer 114 .

[0066] In yet another example, the third compliant stamping surface 2004 and the fourth compliant stamping surface 2006 extend outwardly from the stamping axis 106 .

[0067] Referring generally to Figures 1 and 20-23, by way of example, the present disclosure relates to a system 2008 for stamping a workpiece 102. Figure 1 discloses an example of a mold set 100, which includes a first stamping die 104, a second stamping die 110, and an elastomeric layer 114. Figures 20 and 21 disclose an example of a system 2008 for stamping a workpiece 102, which includes a mold set 2000, which includes a first stamping die 104, a second stamping die 110, and an elastomeric layer 114. The mold set 2000 may also include a second elastomeric layer 2002. Figure 22 discloses an example mold set 100' in which a workpiece 102' is positioned between the first stamping die 104' and the elastomeric layer 114. FIG. 23 discloses an example mold set 100 ″ in which a workpiece 102 ″ is positioned between a first stamping die 104 ″ and an elastomeric layer 114 .

[0068] 1 , 20, and 21, in one or more examples, a system 2008 for stamping a workpiece 102 includes a mold set 2000. The mold set 2000 includes a first stamping die 104, a second stamping die 110, and an elastomeric layer 114. The first stamping die 104 has a given thickness and defines a first molding surface 108. The second stamping die 110 has a given thickness and defines a second molding surface 112 opposite the first molding surface 108. The elastomeric layer 114 has a given thickness and is disposed between the first stamping die 104 and the second stamping die 110. Elastomeric layer 114 defines a first compliant stamping surface 116 opposing first molding surface 108 and defines a second compliant stamping surface 118 opposing second molding surface 112 .

[0069] In another example of the system 2008, the elastomeric layer 114 of the mold set 2000 includes an elastomeric sheet. In a further example, the elastomeric sheet has a uniform thickness. In yet another example, the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0070] In yet another example of the system 2008, the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 are configured to position the workpiece 102 between the first molding surface 108 of the first stamping die 104 and the first compliant stamping surface 116 of the elastomeric layer 114. In a further example, the elastomeric layer 114 is removably secured to the second stamping die 110. In yet another example, the elastomeric layer 114 is configured to conform to the first molding surface 108 of the first stamping die 104 upon engagement of the first molding surface 108 with the workpiece 102, engagement of the workpiece 102 with the first compliant stamping surface 116 of the elastomeric layer 114, and engagement of the second compliant stamping surface 118 of the elastomeric layer 114 with the second molding surface 112 of the second stamping die 110.

[0071] In yet another example of the system 2008, the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 are configured to position the workpiece 102 between the second molding surface 112 of the second stamping die 110 and the second compliant stamping surface 118 of the elastomeric layer 114. In a further example, the elastomeric layer 114 is removably secured to the first stamping die 104. In yet another example, the elastomeric layer 114 is configured to conform to the second molding surface 112 of the second stamping die upon engagement of the second molding surface 112 with the workpiece 102, engagement of the workpiece 102 with the second compliant stamping surface 118 of the elastomeric layer 114, and engagement of the first compliant stamping surface 116 of the elastomeric layer 114 with the first molding surface 108 of the second stamping die 110.

[0072] In yet another example of the system 2008, the elastomeric layer 114 is replaceable.

[0073] In another example of the system 2008, the elastomeric layer 114 is configured to deform from an area of ​​high pressure to an area of ​​low pressure when the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 and the elastomeric layer 114. In a further example, the deformation of the elastomeric layer 114 balances the pressure on the workpiece 102 when the first stamping die 104 and the second stamping die 110 are brought together to compress the workpiece 102 and the elastomeric layer 114.

[0074] In yet another example of the system 2008, the elastomeric layer 114 is configured for use with other mold sets 100 that include different stamping dies 104,110 having different molding surfaces 108,112.

[0075] In yet another example of the system 2008, the workpiece 102 is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material. In a further example, the workpiece 102 is preheated to at least a predetermined melting temperature of the thermoplastic matrix material of the workpiece 102. In yet another example, the system 2008 also includes at least one heater configured to preheat the first stamping die 104, the second stamping die 110, and the elastomeric layer 114 to a predetermined solidification temperature of the thermoplastic matrix material of the workpiece 102.

[0076] In yet another example of system 2008, mold set 2000 also includes a second elastomeric layer 2002 having a thickness along stamping axis 106 and disposed between first stamping die 104 and second stamping die 110 adjacent elastomeric layer 114. Second elastomeric layer 2002 defines a third compliant stamping surface 2004 opposing first molding surface 108 of first stamping die 104 and a fourth compliant stamping surface 2006 opposing second molding surface 112 of second stamping die 110.

[0077] In a further example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the second compliant stamping surface 118 of the elastomeric layer 114 and the third compliant stamping surface 2004 of the second elastomeric layer 2002. In yet another example, the elastomeric layer 114 is removably secured to the first stamping die 104 and the second elastomeric layer 2002 is removably secured to the second stamping die 110.

[0078] In a further example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the fourth compliant stamping surface 2006 of the second elastomeric layer 2002 and the second molding surface 112 of the second stamping die 110. In a further example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the first stamping die 104.

[0079] In yet another example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the first compliant stamping surface 116 of the elastomeric layer 114 and the fourth compliant stamping surface 2006 of the second elastomeric layer 2002. In yet another example, the elastomeric layer 114 is removably secured to the second stamping die 110 and the second elastomeric layer 2002 is removably secured to the first stamping die 104.

[0080] In yet another example, the first stamping die 104, the second stamping die 110, the elastomeric layer 114, and the second elastomeric layer 2002 are configured to position the workpiece 102 between the first molding surface 108 of the first stamping die 104 and the third compliant stamping surface 2004 of the second elastomeric layer 2002. In yet another example, the elastomeric layer 114 and the second elastomeric layer 2002 are removably secured to the second stamping die 110.

[0081] In yet another example, second elastomeric layer 2002 has different properties than elastomeric layer 114 .

[0082] The methods 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, mold sets 100, 2000, and systems 2008 for stamping a workpiece 102 may be associated with or used in the manufacture of aircraft. Also, while an aircraft example is described, the embodiments and principles disclosed herein may be applied to other products in the aerospace industry, and to other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Thus, in addition to aircraft, the embodiments and principles disclosed herein may be applied to the manufacture of stamped workpieces in the manufacture of various types of vehicles and the construction of various types of buildings.

[0083] The above detailed description refers to the accompanying drawings, which show specific embodiments according to the present disclosure. Other embodiments having different structures and operations do not depart from the scope of the present disclosure. Similar reference numerals may refer to the same features, elements, or parts in different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually as an item, or multiple items may be referred to collectively as an item and referred to by similar reference numerals. Furthermore, in this specification, a feature, element, part, or step described in the singular does not exclude the plurality of features, elements, parts, or steps, unless expressly stated otherwise.

[0084] Illustrative and non-exclusive examples of the technical subject matter of the present disclosure are described above, including those that are claimed and those that are not. In this specification, when an "example" is used, it means that one or more features, structures, elements, components, characteristics, and / or operations described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the technical subject matter of the present disclosure. Thus, the terms "one example," "another example," "one or more examples," and similar terms may, but do not necessarily, refer to the same example throughout this disclosure. In addition, technical subject matter characterizing any one example may, but does not necessarily, include technical subject matter characterizing any other example. In addition, technical subject matter characterizing any one example may, but does not necessarily, be combined with technical subject matter characterizing any other example.

[0085] As used herein, a system, apparatus, device, structure, article, element, part, or hardware that is "configured" to perform a particular function refers to something that can perform that particular function without any modification, and not something that requires some modification to perform that particular function. In other words, a system, apparatus, device, structure, article, element, part, or hardware that is "configured" to perform a particular function refers to something that is specifically selected, made, implemented, utilized, programmed, and / or designed to perform that particular function. As used herein, "configured" refers to a characteristic that the system, apparatus, structure, article, element, part, or hardware already has that enables the system, apparatus, structure, article, element, part, or hardware to perform that particular function without any modification. In this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function may additionally or alternatively be described as being "adapted to" and / or "operative to" perform that function.

[0086] The terms "first," "second," "third," etc. are used herein merely as labels, unless otherwise indicated, and do not impose any ordering, positional, or hierarchical requirements on the items to which they refer, and a reference to, for example, a "second" item does not require or exclude the presence of, for example, a "first" item or lower ordinal items, and / or a "third" or higher ordinal items.

[0087] As used herein, the phrase "at least one of" when used in reference to a list of items means that one or more of the listed items may be used in various combinations and that only one of each listed item may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, item A, or item A and item B. This example may also include item A, item B, and item C, or item B and item C. In other examples, "at least one of" may be, but is not limited to, 2 items A, 1 item B, and 10 items C; 4 items B and 7 items C, or other suitable combinations. As used herein, the term "and / or" and the " / " symbol include any and all combinations of one or more of the listed items associated therewith.

[0088] As used herein, the terms "coupled," "connected," and similar terms refer to two or more elements that are joined, coupled, fastened, attached, connected, in communication, or otherwise associated with one another (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, the elements can be directly or indirectly associated. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, e.g., through another element C. It is noted that not all relationships between the various disclosed elements are necessarily shown. Thus, other connections may exist than those shown in the figures.

[0089] As used herein, the term "approximately" refers to a condition that is close to, but not exactly the same as, a described condition that performs a desired function or achieves a desired result. As an example, the term "approximately" refers to a condition that is within an acceptable range of a given tolerance or precision, for example, within 10% of a described condition. However, the term "approximately" does not exclude cases where the condition is exactly that. Also, as used herein, the term "substantially" refers to a condition that is essentially the same as a described condition that performs a desired function or achieves a desired result.

[0090] The above-referenced Figures 1 and 20-23 depict functional elements, features, or components, and do not necessarily imply any particular structure. Thus, modifications, additions, and / or omissions may be made to the illustrated structures. In addition, those skilled in the art will appreciate that not all of the elements, features, and / or components described and illustrated in the above-referenced Figures 1 and 20-23 need to be included in every embodiment, and not all of the elements, features, and / or components described herein are necessarily depicted in each illustrated embodiment. Thus, some of the elements, features, and / or components described and illustrated in Figures 1 and 20-23 may be combined in various ways without including other components described and illustrated in Figures 1 and 20-23, other figures, and / or the accompanying disclosure, without such combinations being expressly set forth in this disclosure. Similarly, additional components not limited to the examples presented may be combined with some or all of the components illustrated and described herein. Unless otherwise indicated, the illustration of the embodiment shown in FIG. 1 and FIG. 20-23 referenced above does not imply structural limitations on the exemplary embodiment. Rather, it is to be understood that one exemplary structure is shown, but that the structure may be varied as appropriate. Thus, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, elements, features, and / or parts that serve similar or at least substantially similar purposes are labeled with similar reference numerals in each of FIG. 1 and FIG. 20-30, and these elements, features, and / or parts may not be described in detail with reference to each of FIG. 1 and FIG. 20-30. Similarly, not all elements, features, and / or parts are labeled in each of FIG. 1 and FIG. 20-23, but the reference numerals associated therewith are used consistently throughout this specification.

[0091] In the above-referenced Figures 2-19, the blocks represent, for example, operations, steps, and / or portions thereof, and the lines connecting the various blocks do not indicate a particular order or dependency of these operations or portions thereof. Furthermore, not all dependencies between the various operations disclosed are necessarily shown. The operations of the disclosed method described herein and the accompanying description should not be construed as necessarily determining the order in which these operations are performed. Rather, although one exemplary order is shown, it should be understood that the order of these operations can be changed as appropriate. Thus, modifications, additions, and / or omissions can be made to the illustrated operations, and some operations can be performed in a different order or simultaneously. Furthermore, it will be apparent to one skilled in the art that it is not necessary to perform all of the steps described.

[0092] Furthermore, throughout this specification, references to features and advantages, and similar language used herein, do not imply that all features and advantages that may be realized in the embodiments disclosed herein should or are present in any one embodiment. Rather, language referring to these features and advantages means that the particular feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, descriptions of features and advantages, and similar language used throughout this disclosure, are not necessarily referring to the same embodiment.

[0093] An embodiment of the subject matter disclosed herein may be described in relation to an aircraft manufacturing and service method 2400 as shown in FIG. 24 and an aircraft 2500 as shown in FIG. 25. In one or more embodiments, the methods, tooling sets, and systems for stamping workpieces according to the present disclosure may be used in the manufacture of aircraft. Before production begins, the service method 2400 includes specification and design of the aircraft 2500 (block 2402) and material procurement (block 2404). During production, the components and subassemblies of the aircraft 2500 are manufactured (block 2406) and systems integrated (block 2408). The aircraft 2500 then undergoes certification and delivery (block 2410) and enters service (block 2412). During the service period, the aircraft 2500 is scheduled for routine maintenance and service (block 2414). Routine maintenance and service may include upgrading, reconfiguration, modification, etc. of one or more systems of aircraft 2500.

[0094] Each step of in-service method 2400 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). A system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors. A third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers. An operator may be, for example, an airline, a leasing company, a military entity, a service organization, etc.

[0095] As shown in FIG. 25 , the aircraft 2500 produced by the method 2400 for entering service may include an airframe 2502 having a number of high level systems 2504 and an interior 2506. Examples of the high level systems 2504 include one or more of a propulsion system 2508, an electrical system 2510, a hydraulic system 2512, and an environmental system 2514. Any number of other systems may also be included. Additionally, while an aerospace example is provided, the principles disclosed herein may be applied to other industries, such as the automotive industry. Thus, in addition to the aircraft 2500, the principles described herein may be applied to other vehicles, such as land vehicles, watercraft, spacecraft, etc.

[0096] Mold sets, systems, and methods for stamping a workpiece according to the present disclosure may be employed at any one or more stages of manufacturing and service method 2400. For example, parts or subassemblies corresponding to the manufacturing process for parts and subassemblies (block 2406) may be similarly made or manufactured as parts or subassemblies made while aircraft 2500 is in service (block 2412). One or more embodiments of the mold sets, systems, methods, or any combination thereof may also be used, for example, during the manufacturing process (blocks 2406 and 2408) to substantially speed up or reduce the cost of assembling aircraft 2500. Similarly, one or more embodiments of the mold sets, systems, methods, or any combination thereof may be used, for example, but not limited to, during the in-service (block 2412) and / or maintenance and service (block 2414) of aircraft 2500.

[0097] Features, advantages, and properties of one embodiment may be incorporated in any suitable manner into one or more other embodiments. Those skilled in the art will appreciate that the embodiments described herein may be practiced without one or more of the specific features or advantages of a particular embodiment. In some cases, additional features and advantages may be observed in a particular embodiment that may not be present in all embodiments. Also, while various embodiment mold sets 100, 2000, systems 2008, and methods 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900 for stamping a workpiece 102 have been shown and described, various modifications will occur to those skilled in the art upon reading this specification. The present application includes such modifications and is intended to be limited only by the scope of the claims.

[0098] Meanwhile, the present disclosure also includes the following notes.

[0099] Supplementary Note 1. A method (200) for stamping a workpiece (102), comprising: positioning (202) the workpiece (102) between a first stamping die (104) and an elastomeric layer (114) opposing the first stamping die (104), the elastomeric layer (114) being disposed between the first stamping die (104) and a second stamping die (110), the first stamping die (104) defining a first molding surface (108), the second stamping die (110) defining a second molding surface (112) opposing the first molding surface (108), the elastomeric layer (114) defining a first compliant stamping surface (116) opposing the first molding surface (108) and a second compliant stamping surface (118) opposing the second molding surface (112); and compressing (204) the workpiece (102) between the first forming surface (108) and the first compliant stamping surface (116) by bringing the first stamping die (104) and the second stamping die (110) closer together.

[0100] Clause 2. The method of clause 1, wherein the elastomeric layer (114) comprises an elastomeric sheet.

[0101] Clause 3. The method of clause 2, wherein the elastomeric sheet has a uniform thickness.

[0102] Appendix 4. The method of appendix 2, wherein the elastomer sheet is a commercially available preformed elastomer sheet.

[0103] Clause 5. The method of clause 1, wherein the elastomeric layer (114) is removably secured to the second stamping mold (110).

[0104] Clause 6. The method of clause 1, further comprising positioning (206) the elastomeric layer (114) between the first stamping die (104) and the second stamping die (110).

[0105] Addendum 7. The method further comprises the steps of: upon reaching a predetermined pressure during the compression (204), deforming (208) the first compliant stamping surface (116) of the elastomeric layer (114) based on a first shape of the first molding surface (108); deforming (210) the second compliant stamping surface (118) of the elastomeric layer (114) based on a second shape of the second molding surface (112); 2. The method of claim 1, further comprising: deforming (212) the workpiece (102) based on the first shape of the first molding surface (108), the deformed first compliant stamping surface (116), the deformed second compliant stamping surface (118), and the second shape of the second molding surface (112).

[0106] Clause 8. The method of clause 7, wherein the predetermined pressure is at least one of about 400 psi or more, about 300 psi or more, about 200 psi or more, and about 100 psi or more.

[0107] Appendix 9. The method of Appendix 7, wherein the first shape of the first molding surface (108) includes at least one of a flat portion, an undulating portion, a protruding portion, an inclined portion, a descending slope portion, a stepped portion, and a convex portion.

[0108] Clause 10. The method of clause 7, wherein the second shape of the second molding surface (112) corresponds to the first shape of the first molding surface (108).

[0109] Clause 11. The method of clause 1, wherein the workpiece (102) is a thermoplastic composite comprising reinforcing fibers embedded in a thermoplastic matrix material.

[0110] Clause 12. The method of clause 11, further comprising preheating (302) the workpiece (102) to at least a predetermined melting point of the thermoplastic matrix material.

[0111] Clause 13. The method of clause 12, wherein the predetermined melting point is in at least one of the following ranges: between about 300°C and about 500°C, between about 300°C and about 400°C, and between about 300°C and about 360°C.

[0112] Clause 14. The method of clause 11, further comprising preheating (304) the first stamping mold (104), the second stamping mold (110), and the elastomeric layer (114) to a predetermined solidification temperature of the thermoplastic matrix material.

[0113] Clause 15. The method of clause 14, wherein the predetermined solidification temperature is in at least one of the following ranges: between about 150°C and about 300°C, between about 200°C and about 300°C, and between about 250°C and about 300°C.

[0114] Clause 16. The method of clause 11, further comprising consolidating (402) the workpiece (102) in response to reaching a predetermined pressure during the compressing (204).

[0115] Clause 17. The method of clause 16, wherein the predetermined pressure is at least one of about 400 psi or more, about 300 psi or more, about 200 psi or more, and about 100 psi or more.

[0116] Clause 18. Separating (502) the first stamping die (104) and the second stamping die (110) to release the workpiece (102); 2. The method of claim 1, further comprising removing (504) the workpiece (102) from between the first molding surface (108) and the first compliant stamping surface (116).

[0117] Clause 19. The method of clause 1, further comprising positioning a second elastomeric layer (2002) between the elastomeric layer (114) and the workpiece (102) in a direction along a stamping axis (106), the second elastomeric layer (2002) defining a third compliant stamping surface (2004) opposite the second compliant stamping surface (118) and a fourth compliant stamping surface (2006) facing toward the workpiece (102) and opposite the second molding surface (112).

[0118] Clause 20. The method of clause 19, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the first stamping mold (104).

[0119] Clause 21. The method of clause 19, wherein the second elastomer layer (2002) has different properties than the elastomer layer (114).

[0120] Addendum 22. The method of Addendum 1, further comprising positioning (602) a second elastomeric layer (2002) between the first stamping die (104) and the workpiece (102) in a direction along a stamping axis (106), the second elastomeric layer (2002) defining a third compliant stamping surface (2004) facing the first molding surface (108) and a fourth compliant stamping surface (2006) facing toward the workpiece (102) and facing the second molding surface (112).

[0121] Clause 23. The method of clause 22, wherein the second elastomeric layer (2002) is removably secured to the first stamping mold (104).

[0122] Addendum 24. The method further comprises the steps of: upon reaching a predetermined pressure during the compression (204), deforming (702) the third compliant stamping surface (2004) of the second elastomeric layer (2002) based on a first shape of the first molding surface (108); deforming (704) the second compliant stamping surface (118) of the elastomeric layer (114) based on a second shape of the second molding surface (112); 23. The method of claim 22, further comprising: deforming (706) the workpiece (102) based on the first shape of the first molding surface (108), the deformed third compliant stamping surface (2004), the deformed second compliant stamping surface (118), and the second shape of the second molding surface (112).

[0123] Clause 25. The method of clause 22, wherein the workpiece (102) is a thermoplastic composite comprising reinforcing fibers embedded in a thermoplastic matrix material.

[0124] Clause 26. The method of clause 25, further comprising preheating (802) the workpiece (102) to at least a predetermined melting point of the thermoplastic matrix material.

[0125] Clause 27. The method of clause 25, further comprising preheating (804) the first stamping mold (104), the second stamping mold (110), the elastomeric layer (114), and the second elastomeric layer (2002) to a predetermined solidification temperature of the thermoplastic matrix material.

[0126] Clause 28. The method of clause 25, further comprising consolidating (902) the workpiece (102) in response to reaching a predetermined pressure during the compressing (204).

[0127] Addendum 29. Separating (1002) the first stamping die (104) and the second stamping die (110) to release the workpiece (102); removing (1004) the second elastomeric layer (2002) and the workpiece (102) from between the second molding surface (112) and the first compliant stamping surface (116); 23. The method of claim 22, further comprising removing (1006) the workpiece (102) from the fourth compliant stamping surface (2006) of the second elastomeric layer (2002).

[0128] Addendum 30. A method (1100) for stamping a workpiece (102), comprising: positioning (1102) a workpiece (102) between a first stamping die (104) and a second stamping die (110), the first stamping die (104) defining a first molding surface (108) and the second stamping die (110) defining a second molding surface (112) opposite the first molding surface (108); positioning (1104) an elastomeric layer (114) between the first stamping die (104) and the workpiece (102), the elastomeric layer (114) defining a first compliant stamping surface (116) facing the first molding surface (108) and a second compliant stamping surface (118) facing the second molding surface (112) and facing the workpiece (102); and compressing (1106) the workpiece (102) between the second compliant stamping surface (118) and a second molding surface (112) by bringing the first stamping die (104) and the second stamping die (110) closer together.

[0129] Clause 31. The method of clause 30, wherein the elastomeric layer (114) comprises an elastomeric sheet.

[0130] Clause 32. The method of clause 31, wherein the elastomeric sheet has a uniform thickness.

[0131] Addendum 33. The method of Addendum 31, wherein the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0132] Clause 34. The method of clause 30, wherein the second elastomeric layer (114) is removably secured to the first stamping mold (104).

[0133] Addendum 35. The method further comprises the steps of: upon reaching a predetermined pressure during the compression (1106), deforming (1108) the first compliant stamping surface (116) of the elastomeric layer (114) based on a first shape of the first molding surface (108); deforming (1110) the second compliant stamping surface (118) of the elastomeric layer (114) based on a second shape of the second molding surface (112); 31. The method of claim 30, further comprising deforming (1112) the workpiece (102) based on the first shape of the first molding surface (108), the deformed first compliant stamping surface (116), the deformed second compliant stamping surface (118), and the second shape of the second molding surface (112).

[0134] Clause 36. The method of clause 30, wherein the workpiece (102) is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material.

[0135] Clause 37. The method of clause 36, further comprising preheating (1202) the workpiece (102) to at least a predetermined melting point of the thermoplastic matrix material.

[0136] Clause 38. The method of clause 36, further comprising preheating (1204) the first stamping mold (104), the second stamping mold (110), and the elastomeric layer (114) to a predetermined solidification temperature of the thermoplastic matrix material.

[0137] Clause 39. The method of clause 36, further comprising consolidating (1302) the workpiece (102) in response to reaching a predetermined pressure during the compressing (1106).

[0138] Clause 40. Separating (1402) the first stamping die (104) and the second stamping die (110) to release the workpiece (102); removing (1404) the elastomeric layer (114) and the workpiece (102) from the second molding surface (112); 31. The method of claim 30, further comprising removing (1406) the workpiece (102) from the second compliant stamping surface of the elastomeric layer (114).

[0139] Clause 41. The method of clause 30, further comprising positioning a second elastomeric layer (2002) between the workpiece (102) and the elastomeric layer (114) in a direction along a stamping axis (106), the second elastomeric layer (2002) defining a third compliant stamping surface (2004) facing toward the workpiece (102) and opposite the first molding surface (108), and a fourth compliant stamping surface (2006) facing the first molding surface (108) of the elastomeric layer (114).

[0140] Clause 42. The method of clause 41, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the second stamping mold (110).

[0141] Clause 43. The method of clause 41, wherein the second elastomeric layer (2002) has different properties than the elastomeric layer (114).

[0142] Clause 44. The method of clause 30, further comprising positioning a second elastomeric layer (2002) between the workpiece (102) and the second stamping die (110) in a direction along a stamping axis (106), the second elastomeric layer (2002) defining a third compliant stamping surface (2004) facing toward the workpiece (102) and opposite the first molding surface (108), and a fourth compliant stamping surface (2006) opposite the second molding surface (112).

[0143] Clause 45. The method of clause 44, wherein the second elastomeric layer (2002) is removably secured to the second stamping mold (110).

[0144] Addendum 46. The method further comprises the steps of: upon reaching a predetermined pressure during the compression (1106), deforming (1602) the second compliant stamping surface (118) of the elastomeric layer (114) based on a first shape of the first molding surface (108); deforming (1604) the third compliant stamping surface (2004) of the elastomeric layer (2002) based on a second shape of the second molding surface (112); 45. The method of claim 44, further comprising deforming (1606) the workpiece (102) based on the first shape of the first molding surface (108), the deformed second compliant stamping surface (118), the deformed third compliant stamping surface (2004), and the second shape of the second molding surface (112).

[0145] Clause 47. The method of clause 44, wherein the workpiece (102) is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material.

[0146] Clause 48. The method of clause 47, further comprising preheating (1702) the workpiece (102) to at least a predetermined melting point of the thermoplastic matrix material.

[0147] Clause 49. The method of clause 47, further comprising preheating (1704) the first stamping mold (104), the second stamping mold (110), the elastomeric layer (114), and the second elastomeric layer (2002) to a predetermined solidification temperature of the thermoplastic matrix material.

[0148] Clause 50. The method of clause 47, further comprising consolidating (1802) the workpiece (102) in response to reaching a predetermined pressure during the compressing (1106).

[0149] Clause 51. Separating (1902) the first stamping die (104) and the second stamping die (110) to release the workpiece (102); removing (1904) the workpiece (102) and the second elastomeric layer (2002) from the second molding surface (112); 45. The method of claim 44, further comprising removing (1906) the workpiece (102) from the third compliant stamping surface of the elastomeric layer (2002).

[0150] Addendum 52. A mold set (100) for stamping a workpiece (102), comprising: a first stamping die (104) having a given thickness and defining a first molding surface (108); a second stamping die (110) having a given thickness and defining a second molding surface (112) opposite said first molding surface (108); a mold set including an elastomeric layer (114) having a given thickness and disposed between said first stamping mold (104) and said second stamping mold (110), said elastomeric layer (114) defining a first compliant stamping surface (116) opposing said first molding surface (108) and a second compliant stamping surface (118) opposing said second molding surface (112).

[0151] Clause 53. The mold set of clause 52, wherein the elastomeric layer (114) comprises an elastomeric sheet.

[0152] Clause 54. The mold set of clause 53, wherein the elastomeric sheet has a uniform thickness.

[0153] Addendum 55. The mold set of Addendum 53, wherein the elastomeric sheet is a commercially available preformed elastomeric sheet.

[0154] Addendum 56. The mold set of Addendum 52, wherein the first stamping die (104), the second stamping die (110), and the elastomeric layer (114) are configured to position the workpiece (102) between the first molding surface (108) of the first stamping die (104) and the first compliant stamping surface (116) of the elastomeric layer (114).

[0155] Clause 57. The mold set of clause 56, wherein the elastomeric layer (114) is removably secured to the second stamping mold (110).

[0156] Clause 58. The mold set of clause 56, wherein the elastomeric layer (114) is configured to conform to the first molding surface (108) of the first stamping die (104) upon engagement of the first molding surface (108) with the workpiece (102), engagement of the workpiece (102) with the first compliant stamping surface (116) of the elastomeric layer (114), and engagement of the second compliant stamping surface (118) of the elastomeric layer (114) with the second molding surface (112) of the second stamping die (110).

[0157] Addendum 59. The mold set of Addendum 52, wherein the first stamping die (104), the second stamping die (110), and the elastomeric layer (114) are configured to position the workpiece (102) between the second molding surface (112) of the second stamping die (110) and the second compliant stamping surface (118) of the elastomeric layer (114).

[0158] Clause 60. The mold set of clause 59, wherein the elastomeric layer (114) is removably secured to the first stamping mold (104).

[0159] CLAIM 61. The mold set of claim 59, wherein the elastomeric layer (114) is configured to conform to the second molding surface (112) of the second stamping mold upon engagement of the second molding surface (112) with the workpiece (102), engagement of the workpiece (102) with the second compliant stamping surface (118) of the elastomeric layer (114), and engagement of the first compliant stamping surface (116) of the elastomeric layer (114) with the first molding surface (108) of the first stamping mold (104).

[0160] Clause 62. The mold set of clause 52, wherein the elastomeric layer (114) is replaceable.

[0161] Addendum 63. The mold set of Addendum 52, wherein the elastomer layer (114) comprises at least one of silicone rubber, neoprene rubber, fluoroelastomer rubber, fiber reinforced rubber, particle reinforced rubber, nitrile rubber, butadiene rubber, urethane rubber, rubber-like material, ethylene propylene diene monomer (EPDM) rubber, foam rubber, sponge rubber, and styrene butadiene rubber.

[0162] Addendum 64. The mold set of Addendum 52, wherein the elastomeric layer (114) has a minimum thickness of about 1 / 32 inch, about 1 / 16 inch, about 1 / 8 inch, about 3 / 16 inch, about 3 / 32 inch, about 1 / 4 inch, about 3 / 8 inch, about 1 / 2 inch, about 3 / 4 inch, about 1 inch, about 1.5 inch, or about 2 inches.

[0163] Addendum 65. The mold set of Addendum 52, wherein the elastomeric layer (114) has a length ranging from about 0.25 feet to about 200 feet, from 0.5 feet to about 100 feet, from about 1 foot to about 50 feet, from about 2 feet to about 25 feet, and from about 4 feet to about 12.5 feet.

[0164] Addendum 66. The mold set of Addendum 52, wherein the elastomeric layer (114) has a height in the range of about 3 inches to about 144 inches, about 6 inches to about 72 inches, and about 12 inches to about 36 inches.

[0165] Addendum 67. The mold set of Addendum 52, wherein the thickness of the elastomeric layer (114) is based, at least in part, on the tolerances of the stamping surfaces of the first stamping die (104) and the second stamping die (110).

[0166] Addendum 68. The mold set of Addendum 52, wherein the thickness of the elastomer layer (114) is based, at least in part, on at least one of a thickness variation of the workpiece (102) and a thickness tolerance of the workpiece (102).

[0167] Addendum 69. The mold set of Addendum 52, wherein the elastomeric layer (114) is configured to deform from a high pressure region to a low pressure region when the first stamping die (104) and the second stamping die (110) are brought close together to compress the workpiece (102) and the elastomeric layer (114).

[0168] Addendum 70. The mold set of Addendum 69, wherein the deformation of the elastomeric layer (114) balances the pressure on the workpiece (102) when the first stamping die (104) and the second stamping die (110) are brought closer together to compress the workpiece (102) and the elastomeric layer (114).

[0169] Appendix 71. The mold set according to Appendix 52, wherein the elastomer layer (114) has a rigidity in at least one range of about 0.1 MPa to about 500 MPa, about 0.5 MPa to about 250 MPa, 1 MPa to about 50 MPa, about 2 MPa to about 25 MPa, and about 4 MPa to about 12.5 MPa.

[0170] Addendum 72. The mold set of Addendum 52, wherein the elastomeric layer (114) has a stiffness that is less than the stiffness of the workpiece (102) when a thermoplastic matrix material of the workpiece (102) turns into a solid at a solidification temperature.

[0171] Addendum 73. The mold set of Addendum 52, wherein the elastomeric layer (114) is configured for use at a maximum temperature of at least one of about 350°C, about 325°C, about 300°C, about 275°C, about 250°C, about 225°C, about 200°C, about 175°C, and about 150°C.

[0172] Addendum 74. The mold set of Addendum 52, wherein the elastomeric layer (114) is configured for use with other mold sets (100) having different stamping dies (104, 110) having different molding surfaces (108, 112).

[0173] CLAIM 75. The mold set of claim 52, wherein the first molding surface (108), the second molding surface (112), the first compliant stamping surface (116), and the second compliant stamping surface (118) extend outwardly from a stamping axis (106).

[0174] Clause 76. The mold set of Clause 52, wherein the first stamping die (104) and the second stamping die (110) are matching dies.

[0175] Clause 77. The mold set of Clause 52, wherein the first stamping die (104) and the second stamping die (110) comprise at least one of a metallic element and a metallic alloy.

[0176] Clause 78. The mold set of Clause 52, wherein the workpiece (102) is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material.

[0177] Addendum 79. The method further comprises: a second elastomer layer (2002) having a thickness along a stamping axis (106), disposed between the first stamping die (104) and the second stamping die (110), and adjacent to the elastomer layer (114); 53. The mold set of claim 52, wherein the second elastomeric layer (2002) defines a third compliant stamping surface (2004) opposing the first molding surface (108) of the first stamping mold (104) and a fourth compliant stamping surface (2006) opposing the second molding surface (112) of the second stamping mold (110).

[0178] Addendum 80. The mold set of Addendum 79, wherein the first stamping die (104), the second stamping die (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the second compliant stamping surface (118) of the elastomeric layer (114) and the third compliant stamping surface (2004) of the second elastomeric layer (2002).

[0179] Addendum 81. The mold set of Addendum 80, wherein the elastomeric layer (114) is removably secured to the first stamping mold (104) and the second elastomeric layer (2002) is removably secured to the second stamping mold (110).

[0180] Addendum 82. The mold set of Addendum 79, wherein the first stamping die (104), the second stamping die (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the fourth compliant stamping surface (2006) of the second elastomeric layer (2002) and the second molding surface (112) of the second stamping die (110).

[0181] Clause 83. The mold set of clause 82, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the first stamping mold (104).

[0182] Addendum 84. The mold set of Addendum 79, wherein the first stamping die (104), the second stamping die (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the first compliant stamping surface (116) of the elastomeric layer (114) and the fourth compliant stamping surface (2006) of the second elastomeric layer (2002).

[0183] Addendum 85. The mold set of Addendum 84, wherein the elastomeric layer (114) is removably secured to the second stamping mold (110) and the second elastomeric layer (2002) is removably secured to the first stamping mold (110).

[0184] Addendum 86. The mold set of Addendum 84, wherein the first stamping die (104), the second stamping die (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the first molding surface (108) of the first stamping die (104) and the third compliant stamping surface (2004) of the second elastomeric layer (2002).

[0185] Clause 87. The mold set of clause 86, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the second stamping mold (110).

[0186] Clause 88. The mold set of clause 84, wherein the second elastomer layer (2002) has different properties than the elastomer layer (114).

[0187] Clause 89. The mold set of Clause 84, wherein the third compliant stamping surface (2004) and the fourth compliant stamping surface (2006) extend outwardly from a stamping axis (106).

[0188] CLAIM 90. A system (2008) for stamping a workpiece (102), the system comprising a mold set (2000), the mold set comprising: a first stamping die (104) having a given thickness and defining a first molding surface (108); a second stamping die (110) having a given thickness and defining a second molding surface (112) opposite said first molding surface (108); an elastomeric layer (114) having a predetermined thickness and disposed between said first stamping die (104) and said second stamping die (110), said elastomeric layer (114) defining a first compliant stamping surface (116) opposing said first molding surface (108) and a second compliant stamping surface (118) opposing said second molding surface (112).

[0189] Clause 91. The system of clause 90, wherein the elastomeric layer (114) of the mold set (2000) comprises an elastomeric sheet.

[0190] Addendum 92. The system of Addendum 91, wherein the elastomeric sheet has a uniform thickness.

[0191] Addendum 93. The system of Addendum 91, wherein the elastomeric sheet is a commercially available, prefabricated elastomeric sheet.

[0192] Addendum 94. The system of Addendum 90, wherein the first stamping die (104), the second stamping die (110), and the elastomeric layer (114) are configured to position the workpiece (102) between the first molding surface (108) of the first stamping die (104) and the first compliant stamping surface (116) of the elastomeric layer (114).

[0193] Clause 95. The system of clause 94, wherein the elastomeric layer (2002) is removably secured to the second stamping mold (110).

[0194] CLAIM 96. The system of claim 94, wherein the elastomeric layer (114) is configured to conform to the first molding surface (108) of the first stamping die (104) upon engagement of the first molding surface (108) with the workpiece (102), engagement of the workpiece (102) with the first compliant stamping surface (116) of the elastomeric layer (114), and engagement of the second compliant stamping surface (118) of the elastomeric layer (114) with the second molding surface (112) of the second stamping die (110).

[0195] Addendum 97. The system of Addendum 90, wherein the first stamping die (104), the second stamping die (110), and the elastomeric layer (114) are configured to position the workpiece (102) between the second molding surface (112) of the second stamping die (110) and the second compliant stamping surface (118) of the elastomeric layer (114).

[0196] Clause 98. The system of clause 97, wherein the elastomeric layer (114) is removably secured to the first stamping mold (104).

[0197] CLAIM 99. The system of claim 97, wherein the elastomeric layer (114) is configured to conform to the second molding surface (112) of the second stamping mold upon engagement of the second molding surface (112) with the workpiece (102), engagement of the workpiece (102) with the second compliant stamping surface (118) of the elastomeric layer (114), and engagement of the first compliant stamping surface (116) of the elastomeric layer (114) with the first molding surface (108) of the first stamping mold (104).

[0198] Clause 100. The system of clause 90, wherein the elastomeric layer (114) is replaceable.

[0199] Addendum 101. The system of Addendum 90, wherein the elastomeric layer (114) is configured to deform from a high pressure region to a low pressure region when the first stamping die (104) and the second stamping die (110) are brought close together to compress the workpiece (102) and the elastomeric layer (114).

[0200] Addendum 102. The system of Addendum 101, wherein the deformation of the elastomeric layer (114) balances the pressure on the workpiece (102) when the first stamping die (104) and the second stamping die (110) are brought closer together to compress the workpiece (102) and the elastomeric layer (114).

[0201] Addendum 103. The system of Addendum 90, wherein the elastomeric layer (114) is configured to be used with another mold set (2000) having a different stamping mold (104, 110) having a different molding surface (108, 112).

[0202] Clause 104. The system of clause 90, wherein the workpiece (102) is a thermoplastic composite including reinforcing fibers embedded in a thermoplastic matrix material.

[0203] Clause 105. The system of clause 104, wherein the workpiece (102) is preheated to at least a predetermined melting point of a thermoplastic matrix material of the workpiece (102).

[0204] Addendum 106. The system of Addendum 104, further comprising at least one heater configured to preheat the first stamping mold (104), the second stamping mold (110), and the elastomeric layer (114) to a predetermined solidification temperature of the thermoplastic matrix material of the workpiece (102).

[0205] Addendum 107. The mold set (2000) comprises: a second elastomeric layer (2002) having a thickness along a stamping axis (106), disposed between the first stamping die (104) and the second stamping die (110), and adjacent to the elastomeric layer (114); 91. The system of claim 90, wherein the second elastomer layer (2002) defines a third compliant stamping surface (2004) facing the first molding surface (108) of the first stamping mold (104) and a fourth compliant stamping surface (2006) facing the second molding surface (112) of the second stamping mold (110).

[0206] Addendum 108. The system of Addendum 107, wherein the first stamping die (104), the second stamping die (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the second compliant stamping surface (118) of the elastomeric layer (114) and the third compliant stamping surface (2004) of the second elastomeric layer (2002).

[0207] Addendum 109. The system of Addendum 108, wherein the elastomeric layer (114) is removably secured to the first stamping mold (104) and the second elastomeric layer (2002) is removably secured to the second stamping mold (110).

[0208] Addendum 110. The system of Addendum 107, wherein the first stamping mold (104), the second stamping mold (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the fourth compliant stamping surface (2006) of the second elastomeric layer (2002) and the second molding surface (112) of the second stamping mold (110).

[0209] Clause 111. The system of clause 110, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the first stamping mold (104).

[0210] Addendum 112. The system of Addendum 107, wherein the first stamping mold (104), the second stamping mold (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the first compliant stamping surface (116) of the elastomeric layer (114) and the fourth compliant stamping surface (2006) of the second elastomeric layer (2002).

[0211] Addendum 113. The system of Addendum 112, wherein the elastomeric layer (114) is removably secured to the second stamping mold (110) and the second elastomeric layer (2002) is removably secured to the first stamping mold (104).

[0212] Addendum 114. The system of Addendum 107, wherein the first stamping mold (104), the second stamping mold (110), the elastomeric layer (114), and the second elastomeric layer (2002) are configured to position the workpiece (102) between the first molding surface (108) of the first stamping mold (104) and the third compliant stamping surface (2004) of the second elastomeric layer (2002).

[0213] Clause 115. The system of clause 114, wherein the elastomeric layer (114) and the second elastomeric layer (2002) are removably secured to the second stamping mold (110).

[0214] Clause 116. The system of clause 107, wherein the second elastomeric layer (2002) has different properties than the elastomeric layer (114).

Claims

1. 1. A method for stamping a workpiece, comprising: positioning the workpiece between a first stamping die and an elastomeric layer opposing the first stamping die, the elastomeric layer being disposed between the first stamping die and a second stamping die, the first stamping die defining a first molding surface, the second stamping die defining a second molding surface opposing the first molding surface, the elastomeric layer defining a first compliant stamping surface opposing the first molding surface and a second compliant stamping surface opposing the second molding surface; compressing the workpiece between the first forming surface and the first compliant stamping surface by bringing the first stamping die and the second stamping die closer together.

2. The method of claim 1 , wherein the elastomeric layer comprises an elastomeric sheet.

3. The method of claim 2 , wherein the elastomeric sheet has a uniform thickness.

4. The method of claim 1 , wherein the elastomeric layer is removably secured to the second stamping mold.

5. The method further comprises the steps of: deforming the first compliant stamping surface of the elastomeric layer based on a first shape of the first molding surface; deforming the second compliant stamping surface of the elastomeric layer based on a second shape of the second molding surface; 2. The method of claim 1, further comprising: deforming the workpiece based on the first shape of the first molding surface, the deformed first compliant stamping surface, the deformed second compliant stamping surface, and the second shape of the second molding surface.

6. The method of claim 7 , wherein the first shape of the first molding surface includes at least one of a flat portion, an undulating portion, a protruding portion, an inclined portion, a declining portion, a stepped portion, and a convex portion.

7. The method of claim 1 , wherein the workpiece is a thermoplastic composite comprising reinforcing fibers embedded in a thermoplastic matrix material.

8. The method of claim 7 further comprising preheating the workpiece to at least a predetermined melting temperature of the thermoplastic matrix material.

9. 8. The method of claim 7, further comprising preheating the first stamping mold, the second stamping mold, and the elastomeric layer to a predetermined solidification temperature of the thermoplastic matrix material.

10. The method of claim 7 further comprising consolidating the workpiece in response to reaching a predetermined pressure during said compressing.

11. 11. The method of claim 1, further comprising positioning a second elastomeric layer between the elastomeric layer and the workpiece in a direction along a stamping axis, the second elastomeric layer defining a third compliant stamping surface opposite the second compliant stamping surface and a fourth compliant stamping surface facing the workpiece and opposite the second molding surface.

12. The method of claim 11 , wherein the elastomeric layer and the second elastomeric layer are removably secured to the first stamping mold.

13. The method of claim 11 , wherein the second elastomeric layer has different properties than the elastomeric layer.

14. 1. A mold set for stamping a workpiece, comprising: a first stamping die having a given thickness and defining a first molding surface; a second stamping die having a given thickness and defining a second molding surface opposite the first molding surface; a layer of elastomer having a given thickness and disposed between the first stamping die and the second stamping die, the layer of elastomer defining a first compliant stamping surface opposing the first molding surface and a second compliant stamping surface opposing the second molding surface.

15. The mold set of claim 14 , wherein the elastomeric layer comprises an elastomeric sheet.

16. 16. The mold set of claim 15, wherein the elastomeric sheet has a uniform thickness.

17. The mold set of claim 14 , wherein the elastomeric layer is removably secured to the second stamping mold.

18. The mold set of claim 14 , wherein the elastomeric layer is removably secured to the first stamping mold.

19. 15. The mold set of claim 14, wherein the elastomeric layer comprises at least one of silicone rubber, neoprene rubber, fluoroelastomer rubber, fiber reinforced rubber, particle reinforced rubber, nitrile rubber, butadiene rubber, urethane rubber, rubber-like material, ethylene propylene diene monomer (EPDM) rubber, foam rubber, sponge rubber, and styrene butadiene rubber.

20. 15. The mold set of claim 14, wherein the elastomeric layer has a stiffness less than a stiffness of the workpiece when a thermoplastic matrix material of the workpiece turns into a solid at a solidification temperature.

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