Multi-chamber compliant bladder for composite part tooling

Abstract

To provide an improved device, system and method for a composite part tooling, in which a sufficient compaction pressure is applied to a mold line shape of a complex thermoplastic composite material, and an influence of thermal expansion in a molding is hardly caused.SOLUTION: A tool for forming a part includes a first tool portion including a first tool surface. The tool further includes a second tool portion including a second tool surface facing the first tool surface, in which the first tool surface and the second tool surface define a tool chamber for forming the part. The tool further includes a bladder subassembly disposed in the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within the tool chamber, in which each inner bladder includes an inner bladder chamber that is independently inflatable to selectively apply pressure to the part. The bladder subassembly further includes a bladder cover.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] The embodiments described herein relate to bladder presses, and more particularly, to multi-chamber compliant bladder presses for composite part tooling, as well as related devices, systems, and methods.

Background Art

[0002] In the manufacture of aerospace-level quality composite parts, conventional molding processes can rapidly process the molding of parts, but there are limitations that make the manufacture of complex composite parts more difficult. For example, thermoplastic composites, when used in appropriate applications, offer a wide range of cycle time and cost advantages, but may not be easily manufacturable by conventional methods. For example, the composite mold line shape of thermoplastic composites often cannot be manufactured with conventional clam shell type molds where the mold parts move in a substantially vertical tool opening and closing direction. Current tooling systems typically do not provide sufficient consolidation pressure for complex thermoplastic composite mold line shapes. Further, due to the effects of thermal expansion in the molding of thermoplastic composite parts, it becomes difficult to achieve aerospace-level quality using conventional tooling. Therefore, improved devices, systems, and methods for composite part tooling for these and other applications are needed.

Summary of the Invention

Means for Solving the Problems

[0003] According to one embodiment, a tool for forming a component is disclosed. The tool includes a first tool portion including a first tool surface. The tool further includes a second tool portion including a second tool surface facing the first tool surface, and the first tool surface and the second tool surface define a tool chamber for forming a component. The tool further includes a bladder subassembly disposed within the tool chamber between the first tool surface and the second tool surface. The bladder subassembly includes a plurality of inner bladders disposed within the tool chamber, and each inner bladder of the plurality of inner bladders includes an inner bladder chamber that is independently inflatable to selectively apply pressure to a component within the tool chamber. The bladder subassembly further includes a bladder cover disposed on the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the component.

[0004] According to one embodiment and any of the foregoing embodiments, each of the plurality of inner bladders includes a substantially linear tube, and the plurality of inner bladders are arranged in an array within the tool chamber.

[0005] According to one embodiment and any of the foregoing embodiments, the bladder cover includes a flexible sheet, and each inner bladder includes a flexible tube defining the inner bladder chamber.

[0006] According to one embodiment and any of the foregoing embodiments, the tool further includes a first end cap disposed at a first end of the tool, and the first end cap includes a first end cap portion and a second end cap portion. The first end cap portion and the second end cap portion clamp a first end of the flexible sheet therebetween. To isolate the inner bladder chambers of the inner bladders within the tool chamber, the first end cap portion and the second end cap portion further clamp a first end of the flexible tube of each inner bladder therebetween.

[0007] According to one embodiment and any of the aforementioned embodiments, the tool further includes a plurality of inlet tubes, each inlet tube of the plurality of inlet tubes extending from the inner bladder chamber of a respective inner bladder to an exterior of the tool, and the first end cap portion and the second end cap portion clamp the inlet tube of each inner bladder therebetween.

[0008] According to one embodiment and any of the aforementioned embodiments, the tool further comprises a plurality of retention elements coupled to the first end cap, each retention element of the plurality of retention elements retaining a respective inlet tube within a respective inner bladder to inhibit movement of the inlet tube relative to the inner bladder.

[0009] According to one embodiment and any of the previous embodiments, the bladder further comprises an outer bladder enclosing the plurality of inner bladders, the outer bladder comprising a bladder cover.

[0010] According to one embodiment and any of the previously described embodiments, the bladder cover and the inner bladder comprise a flexible material, and the inner bladder is integral with the bladder cover.

[0011] According to one embodiment and any of the aforementioned embodiments, a first inner bladder of the plurality of inner bladders and a second inner bladder of the plurality of inner bladders include a shared wall therebetween.

[0012] According to one embodiment and any of the aforementioned embodiments, a bladder for a tool is disclosed. The bladder includes a plurality of inner bladders arranged in an array within a tool chamber of the tool. Each inner bladder of the plurality of inner bladders includes an independently inflatable inner bladder chamber for selectively applying pressure to a component within the tool chamber of the tool. The bladder further includes a bladder cover covering the plurality of inner bladders to provide a barrier between the plurality of inner bladders and the component within the tool chamber.

[0013] According to one embodiment and any of the foregoing embodiments, each of the plurality of inner bladders includes a substantially linear tube, and the plurality of inner bladders are arranged in an array within the tool chamber.

[0014] According to one embodiment and any of the foregoing embodiments, the bladder cover includes a flexible sheet, and each inner bladder includes a flexible tube that defines an inner bladder chamber.

[0015] According to one embodiment and any of the foregoing embodiments, the bladder further includes a plurality of inlet tubes, and each inlet tube of the plurality of inlet tubes extends from the inner bladder chamber of a respective inner bladder to the outside of the inner bladder chamber.

[0016] According to one embodiment and any of the foregoing embodiments, the bladder cover and the inner bladder include a flexible material, and the inner bladder is integral with the bladder cover.

[0017] According to one embodiment and any of the foregoing embodiments, a method is disclosed. The method includes placing a workpiece in a tool chamber of a tool. The tool includes a first tool portion that includes a first tool surface. The tool further includes a second tool portion that includes a second tool surface that faces the first tool surface, and the first tool surface and the second tool surface define the tool chamber. The method further includes placing a bladder subassembly in the tool chamber between the first tool surface and the second tool surface, the step including placing a plurality of inner bladders in the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber, and placing a bladder cover on the plurality of inner bladders in the tool chamber to provide a barrier between the plurality of inner bladders and the workpiece. The method further includes independently inflating the plurality of inner bladders to selectively apply pressure to the workpiece in the tool chamber to form a part.

[0018] According to one embodiment and any of the foregoing embodiments, the method further includes fixing the first tool portion to the second tool portion to form an airtight seal around the tool chamber before the step of inflating the plurality of inner bladders.

[0019] According to one embodiment and any of the foregoing embodiments, the step of inflating the plurality of inner bladders further includes the step of inflating the plurality of inner bladders with gas.

[0020] According to one embodiment and any of the foregoing embodiments, the step of inflating the plurality of inner bladders further includes the step of inflating the plurality of inner bladders with liquid.

[0021] According to one embodiment and any of the foregoing embodiments, the step of inflating the plurality of inner bladders further includes the step of inflating at least two of the plurality of inner bladders to different pressures.

[0022] According to one embodiment and any of the foregoing embodiments, the step of inflating the plurality of inner bladders further includes the step of inflating at least two of the plurality of inner bladders at different times.

Brief Description of the Drawings

[0023]

Figure 1A

Figure 1B

Figure 1C

Figure 1D

Figure 2A

Figure 2B

Figure 2C

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 5C

Figure 5D

Figure 6

DETAILED DESCRIPTION OF THE INVENTION

[0024] FIELD OF THE INVENTION The embodiments described herein relate to bladders, and more particularly to multi-chamber conformal bladders for thermoplastic tooling, and related devices, systems, and methods.

[0025] 1A-1D are perspective views of a tool 100 for forming a part 112 using a bladder subassembly 114, illustrating the assembly of the tool 100 around a workpiece 160, according to one embodiment. The tool 100 forms the part 112 from the workpiece 160. The tool 100 includes a first tool portion 102 having a first tool surface 106 and a second tool portion 104 having a second tool surface 108 facing the first tool surface 106. The first tool surface 106 and the second tool surface 108 define a tool chamber 110 for forming the part 112. The tool 100 includes a bladder subassembly 114 disposed within the tool chamber 110 between the first tool surface 106 and the second tool surface 108.

[0026] The bladder subassembly 114 includes a plurality of inner bladders 116 disposed within the tool chamber 110 and a bladder cover 120 disposed over the plurality of inner bladders 116 within the tool chamber 110 to provide a barrier between the plurality of inner bladders 116 and the thermoplastic component 112. Each inner bladder 116 includes an inner bladder chamber 118 that is independently inflatable to selectively apply pressure to the thermoplastic component 112 within the tool chamber 110.

[0027] In this example, the bladder cover 120 is a flexible sheet 128 that covers a plurality of inner bladders 116. Each inner bladder 116 includes a substantially straight flexible tube 124 that defines a respective inner bladder chamber 118, and the inner bladders 116 are arranged in an array 126 within the tool chamber 110.

[0028] As shown in Figure 1A, the bladder subassembly 114 is positioned on the first tool surface 106 of the first tool piece 102, and the workpiece 160 forming the part 112 is positioned between the first tool piece 102 and the second tool piece 104. As shown in Figure 1B, the bladder subassembly 114 is substantially deflated and does not exert substantial pressure on the workpiece 160 during assembly.

[0029] 1C, in this embodiment, a first end cap 130 is attached to a first end 132 (see FIG. 1A) of the tool 100. As shown in FIGS. 2B and 2C, a second end cap 146 is also attached to a second end 148 of the tool 100 opposite the first end 132. The first end cap 130 includes a first end cap portion 134 and a second end cap portion 136 that clamp therebetween a first end 138 (see FIGS. 2B and 2C) of the flexible sheet 128 of the bladder cover 120 and a first end 140 (see FIGS. 2B and 2C) of the flexible tube 124 of the inner bladder 116. The second end cap 146 in this embodiment includes a third end cap portion 150 and a fourth end cap portion 152 that clamp therebetween a second end 154 (see FIG. 1A ) of the flexible sheet 128 of the bladder cover 120 and a second end 156 (see FIG. 1A ) of the flexible tube 124 of the inner bladder 116. In this manner, the first end cap 130 and the second end cap 146 isolate the inner bladder chamber 118 within the tool chamber 110.

[0030] In this embodiment, a plurality of inlet tubes 142 extend from respective inner bladder chambers 118 of the inner bladders 116 to the exterior 144 of the tool 100. The plurality of inlet tubes 142 are clamped between a first end cap portion 134 and a second end cap portion 136 of the first end cap 130, enabling each inner bladder 116 to be inflated independently to apply pressure to the thermoplastic workpiece 160 to form the thermoplastic part 112. Additional bracing components 170 and support components 172 are attached around the tool 100, as shown by FIGS. 1C and 1D, to further secure the tool 100 and prevent movement of the tool portions 102, 104, end caps 130, 146, or other components during formation of the part 112. In this embodiment, a third end cap portion 150 and a fourth end cap portion 152 of the second end cap 146 completely seal the second ends 154, 156 of the flexible sheet 128 and the flexible tubes 124 of the inner bladders 116, but it should be understood that in another embodiment, additional inlet tubes can be disposed in the second end cap 146 to inflate the inner bladders 116 independently from both ends of the tool 100.

[0031] Referring now to FIGS. 2A-2C, cross-sectional views of the tool 100 of FIGS. 1A-1D showing the components of the bladder subassembly 114 are shown. Referring now to FIG. 2A, a cross-section of the tool 100 shows the inner bladders 116 arranged in an array 126 along the first tool surface 106 of the first tool portion 102. The flexible sheet 128 of the bladder cover 120 provides a barrier between the inner bladders 116 and components (not shown) within the tool chamber 110. One advantage of using the bladder cover 120 between the inner bladders 116 and the components is that the bladder cover 120 helps keep the surface of the components smooth during inflation of the inner bladders 116, otherwise reducing the appearance of seams that may form in the components at the joints between the inner bladders 116. In this example, the bladder cover 120 is less flexible than the inner bladders 116 to reduce the appearance of wrinkles or seams (e.g., marks off) between the bladders, but it should be understood that the flexibility of the inner bladders 116 and / or the bladder cover 120 can be customized based on the materials used and the desired properties of the finished part 112.

[0032] Referring now to FIGS. 2B and 2C, a longitudinal cross-sectional view of the tool 100 shows the assembly of the tool 100 around the workpiece 160 for forming the part 112. As described above, to isolate the inner bladder chamber 118 of the inner bladder 116 within the tool chamber 110, the first end cap portion 134 and the second end cap portion 136 of the first end cap 130 clamp therebetween the first end 138 of the flexible sheet 128 of the bladder cover 120 and the first end 140 of the flexible tube 124 of the inner bladder 116. As will be described in more detail below with respect to FIGS. 5A-5D, the first end cap 130 also holds therebetween a plurality of inlet tubes 142 to provide for selective inflation of the individual inner bladders 116. In this embodiment, each of the individual inner bladders 116 has a corresponding inlet tube 142, but it should be further understood that the exact number of inlet tubes 142 and / or inner bladders 116 shown in the various figures may vary for simplicity of presentation. In another embodiment, a plurality of inner bladders 116 can be selectively inflated by one or more common inlet tubes 142 as needed.

[0033] The second end cap 146 of this embodiment includes a third end cap portion 150 and a fourth end cap portion 152 that clamp therebetween the second end 154 of the flexible sheet 128 of the bladder cover 120 and the second end 156 of the flexible tube 124 of the inner bladder 116. In this way, the first end cap 130 and the second end cap 146 isolate the inner bladder chamber 118 within the tool chamber 110.

[0034] One advantage of this embodiment is that variable pressure can be selectively applied across different regions of the composite material during the tooling process. For example, during the weight reduction and consolidation cycles for tooling a thermoplastic part, the bladder cover 120 provides a continuous contact surface at the material interface between the bladder subassembly 114 and the part 112, while at the same time enabling different pressures to be applied at different times to different zones of the part 112 without the need for a more complex tooling arrangement. This helps to prevent inconsistencies and defects in the composite material of the part 112 while reducing wrinkles and mold lines in the finished part 112.

[0035] This embodiment also enables a targeted dynamic adjustment to the pressure applied to different parts of the part 112 at different times. For example, during the crystallization stage of the part 112, increased pressure can be applied to the corners of the part 112. A trial-and-error process can be used to apply different processes to a plurality of test parts 112 to optimize the pressure application process for the part 112, and the regions of the part 112 that receive more pressure vary based on the shape and complexity of the part 112. For example, the pressure can first be applied to the center of the part 112, and the successive adjacent inner bladders 116 continuously increase to press the wrinkles towards the edges of the part 112.

[0036] FIG. 3 is a cross-sectional view of a tool 300 having an alternative bladder subassembly 314 that includes a flexible outer bladder 322 enclosing a plurality of inner bladders 316 according to another embodiment. In this example, a first tool portion 102 having a first tool surface 106 and a second tool portion 104 having a second tool surface forming a tool chamber are the same as in the embodiments of FIGS. 1A - 2 above. However, in this embodiment, the bladder cover 320 is part of the outer bladder 322 that encloses the inner bladders 316 within the outer bladder chamber 323. One advantage of this embodiment is that the entire bladder subassembly 314 can be more easily installed, removed, or replaced within the tool chamber 110 without individually removing the inner bladders 316. In this embodiment, the outer bladder 322 is independently inflatable.

[0037] FIG. 4 is a cross-sectional view of a tool 400 having an alternative bladder assembly 414 that includes an outer bladder 422 integral with a plurality of inner bladders 416, according to another embodiment. In this example, a first tool portion 102 having a first tool surface 106 and a second tool portion 104 having a second tool surface that forms a tool chamber are the same as in the embodiments of FIGS. 1A-2 above. However, in this embodiment, the bladder cover 420 is part of a flexible outer bladder 422 that includes a plurality of single walls 458 therein. The single walls 458 and the outer bladder 422 form a plurality of inner bladders 416, and each pair of adjacent inner bladders 416 (see, e.g., inner bladders 416a and 416b) includes a shared wall 458a therebetween. One advantage of this embodiment is that the bladder sub-assembly 414 can be formed as a single component, reducing the complexity of installing the bladder sub-assembly 414 and preventing the individual inner bladders 416 from moving or shifting relative to each other.

[0038] As discussed above with respect to FIGS. 1A-1D, the plurality of inlet tubes 142 extend from respective inner bladder chambers 118 of the inner bladder 116 to the exterior of the tool 100. In this regard, FIGS. 5A-5D are detailed perspective views of the first end cap 130 and the inlet tubes 142 of FIGS. 1A-1D, showing the components and their details. As shown in FIG. 5A, each inlet tube 142 is clamped between a first end cap portion 134 and a second end cap portion 136 during assembly of the tool 100 to position a portion of each inlet tube 142 within the respective inner bladder 116 (see FIGS. 1A-1D). As shown in FIGS. 5B-5D, each inlet tube 142 is secured to the end cap 130 by a retaining element 143 (a C-clip in this embodiment) that extends around the inlet tube 142 to engage an inner surface 168 of the retaining element 143 (see FIG. 5D) with a narrow portion 158 of the inlet tube 142 (see FIG. 5C) to inhibit movement of the retaining element 143 relative to the respective inner bladder 116. This configuration holds the first end 162 of the inlet tube 142 at the exterior 144 of the tool 100, holds the second end 164 of the inlet tube 142 within the respective inner bladder 116, and prevents the inlet tube 142 from being expelled from the inner bladder 116 during inflation by the higher pressure within the inner bladder 116. As also shown in FIGS. 5C and 5D, the second end cap portion 136 includes a sealing ridge form 166 and an inlet tube groove 167 that engages a complementary form (not shown) of the first end cap portion 134 to more securely hold the inlet tube 142 between the inner bladder 116 and the bladder cover 120.

[0039] FIG. 6 is a flowchart diagram of a method 600 for forming a component using the tools of FIGS. 1A-1D, according to one embodiment. Method 600 includes placing a workpiece 160 within a tool chamber 110 of a tool 100 (block 602). The tool includes a first tool portion 102 that includes a first tool surface 106 and a second tool portion 104 that includes a second tool surface 108 that faces the first tool surface 106, and the first tool surface 106 and the second tool surface 108 define the tool chamber 110. Method 600 further includes placing a bladder subassembly 114 within the tool chamber 110 between the first tool surface 106 and the second tool surface 108 (block 604), and block 604 includes placing a plurality of inner bladders 116 within the tool chamber 110 each having an inner bladder chamber 118 (block 606) and placing a bladder cover 120 on the plurality of inner bladders 116 within the tool chamber 110 to provide a barrier between the plurality of inner bladders 116 and the workpiece 160 (block 608). Method 600 further includes securing the first tool portion 102 to the second tool portion 104 to form an airtight seal around the tool chamber 110 (block 610). Method 600 further includes independently expanding a plurality of inner bladders 116 to selectively apply pressure to the workpiece 160 within the tool chamber 110 to form a component 112 (block 612). In this embodiment, the inner bladders 116 are inflated with gas as needed based on the characteristics of the tool 100, the workpiece 160, and the bladder subassembly 114. In another embodiment, the plurality of inner bladders are inflated with liquid as needed based on the characteristics of the tool 100, the workpiece 160, and the bladder subassembly 114. In another embodiment, at least two of the plurality of inner bladders 116 are inflated to different pressures to affect the final shape of the component 112. In another embodiment, at least two of the plurality of inner bladders 116 are inflated at different times, for example, to cause a wave action on the workpiece 160 during component formation and help smooth the outer surface of the finished component 112.

[0040] As will be understood by those skilled in the art, aspects of the present disclosure include any of several patentable classes or contexts, including any novel and useful process, machine, manufacture, or composition of matter, or any novel and useful improvement thereof, which may be exemplified and described herein.

[0041] The terms used herein are for the purpose of describing particular aspects only and are not intended to limit the disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms "comprising" and "including" specify the presence of the stated form, step, operation, element, or component, but do not preclude the presence or addition of one or more other forms, steps, operations, elements, components, or groups thereof. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items and may be designated as " / ". Like reference numerals mean like elements throughout the description of the figures.

[0042] In connection with the above description and drawings, many different embodiments are disclosed herein. It will be understood that it would be overly repetitive and obfuscating to literally describe and exemplify all combinations and sub-combinations of these embodiments. Accordingly, all embodiments may be combined in any manner or combination, and this specification, including the drawings, is to be construed as constituting a complete written description of all combinations and sub-combinations of the embodiments described herein, as well as the methods and processes of making and using them, and is to be considered as supporting claims directed to such combinations or sub-combinations.

Description of Reference Numerals

[0043] 100 tool 102 first tool part 104 Second tool part 106 First tool surface 108 Second tool surface 110 Tool chamber 112 Part 114 Bladder sub - assembly 116 Inner bladder 118 Inner bladder chamber 120 Bladder cover 124 Flexible tube 126 Array 128 Flexible sheet 130 First end - cap 132 First end 134 First end - cap part 136 Second end - cap part 138 First end 140 First end 142 Inlet tube 143 Holding element 144 Exterior 146 Second end - cap 148 Second end 150 Third end - cap part 152 Fourth end - cap part 154 Second end 156 Second end 158 Narrow part 160 Workpiece 162 First end 164 Second end 166 Sealing ridge form 167 Inlet tube groove 168 Inner surface 170 Bracing component 172 Support component 300 Tool 314 Bladder sub - assembly 316 Inner bladder 320 Bladder cover 322 Outer bladder 323 Outer bladder chamber 400 Tool 414 Bladder Subassembly 416 Inner Bladder 416a Inner Bladder 416b Inner Bladder 420 Bladder Cover 422 Outer Bladder 458 Single Wall 458a Shared Wall

Claims

1. A tool for forming a component, the tool comprising: a first tool portion including a first tool surface; a second tool portion including a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the component; a bladder sub-assembly disposed within the tool chamber between the first tool surface and the second tool surface, the bladder sub-assembly comprising: a plurality of inner bladders disposed within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber that is independently inflatable to selectively apply pressure to the component within the tool chamber; a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the component; a first end cap disposed at a first end of the tool, the first end cap comprising a first end cap portion and a second end cap portion; a plurality of inlet tubes, each inlet tube of the plurality of inlet tubes extending from the inner bladder chamber of a respective inner bladder to the exterior of the tool; a bladder sub-assembly; and wherein the first end cap portion and the second end cap portion clamp the bladder cover and a first end of the inlet tube of each inner bladder therebetween to isolate the inner bladder chamber of each inner bladder within the tool chamber. A tool as claimed in claim 1.

2. The tool according to claim 1, wherein each inner bladder of the plurality of inner bladders comprises a substantially linear tube, and the plurality of inner bladders are arranged in an array within the tool chamber.

3. The tool according to claim 1 or 2, wherein the bladder cover comprises a flexible sheet, and each inner bladder comprises a flexible tube defining the inner bladder chamber. A tool as claimed in claim 1 or 2.

4. A tool for forming a component, the tool comprising: a first tool portion including a first tool surface; A second tool portion including a second tool surface facing the first tool surface, wherein the first tool surface and the second tool surface define a tool chamber for forming the part, the second tool portion; A bladder subassembly disposed within the tool chamber between the first tool surface and the second tool surface, the bladder subassembly comprising: A plurality of inner bladders disposed within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber that is independently inflatable to selectively apply pressure to the part within the tool chamber, the plurality of inner bladders; A bladder cover disposed on the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the part Comprising a bladder subassembly Comprising The bladder cover comprises a flexible sheet; Each inner bladder comprises a flexible tube defining the inner bladder chamber; The tool further comprises a first end cap disposed at a first end of the tool, the first end cap comprising a first end cap portion and a second end cap portion, the first end cap portion and the second end cap portion clamping a first end of the flexible sheet therebetween; The tool, wherein the first end cap portion and the second end cap portion clamp a first end of the flexible tube of each inner bladder therebetween to isolate the inner bladder chamber of the inner bladder within the tool chamber. Claim 5 The tool further comprises a plurality of inlet tubes, each inlet tube of the plurality of inlet tubes extending from the inner bladder chamber of a respective inner bladder to the exterior of the tool. The first end cap portion and the second end cap portion clamp the inlet tube of each inner bladder therebetween. The tool according to claim 4. Claim 6 The tool according to claim 5, further comprising a plurality of retaining elements coupled to the first end cap, each retaining element of the plurality of retaining elements retaining a respective inlet tube within a respective inner bladder to inhibit movement of the inlet tube relative to the inner bladder. Claim 7 A tool for forming a component, the tool comprising: a first tool portion including a first tool surface; a second tool portion including a second tool surface facing the first tool surface, the first tool surface and the second tool surface defining a tool chamber for forming the component; a bladder subassembly disposed within the tool chamber between the first tool surface and the second tool surface, the bladder subassembly comprising: a plurality of inner bladders disposed within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber that is independently inflatable to selectively apply pressure to the component within the tool chamber; a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the component; and a bladder subassembly; an outer bladder enclosing the plurality of inner bladders within an outer bladder chamber, the outer bladder comprising the bladder cover; and a tool. **Claim 8** A tool for forming a component, the tool comprising: a first tool portion including a first tool surface; a second tool portion including a second tool surface facing the first tool surface, the first tool surface and the second tool surface defining a tool chamber for forming the component; a bladder subassembly disposed within the tool chamber between the first tool surface and the second tool surface, the bladder subassembly comprising: a plurality of inner bladders disposed within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber that is independently inflatable to selectively apply pressure to the component within the tool chamber; a bladder cover disposed over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the component; and a bladder subassembly; and further comprising: the bladder cover and the inner bladders comprising a flexible material; and the inner bladders being integral with the bladder cover. **Claim 9** The tool according to claim 8, wherein the first inner bladder of the plurality of inner bladders and the second inner bladder of the plurality of inner bladders have a shared wall therebetween.

10. A bladder for a tool, a plurality of inner bladders disposed within a tool chamber of the tool, each inner bladder of the plurality of inner bladders comprising an inner bladder chamber that is independently inflatable to selectively apply pressure to components within the tool chamber of the tool; a plurality of inner bladders, a bladder cover covering the plurality of inner bladders to provide a barrier between the plurality of inner bladders and the components within the tool chamber a plurality of inlet tubes, each inlet tube of the plurality of inlet tubes extending from the inner bladder chamber of a respective inner bladder to the exterior of the tool, comprising wherein the bladder cover and the inner bladders comprise a flexible material, the inner bladders being integral with the bladder cover.

11. The bladder according to claim 10, wherein each of the plurality of inner bladders comprises a substantially straight tube, and the plurality of inner bladders are arranged in an array within the tool chamber.

12. The bladder cover comprises a flexible sheet, each inner bladder comprising a flexible tube defining the inner bladder chamber. The bladder according to claim 10 or 11.

13. A bladder for a tool, a plurality of inner bladders disposed within a tool chamber of the tool, each inner bladder of the plurality of inner bladders comprising an inner bladder chamber that is independently inflatable to selectively apply pressure to components within the tool chamber of the tool; a plurality of inner bladders, a bladder cover covering the plurality of inner bladders to provide a barrier between the plurality of inner bladders and the components within the tool chamber comprising wherein the bladder cover and the inner bladders comprise a flexible material, the inner bladders being integral with the bladder cover.

14. A method of forming a component, comprising the step of placing a workpiece within a tool chamber of a tool, the tool comprising a first tool portion including a first tool surface and a second tool portion including a second tool surface facing the first tool surface, the first tool surface and the second tool surface defining the tool chamber. The step of disposing a bladder sub-assembly within the tool chamber between the first tool surface and the second tool surface, The step of disposing a plurality of inner bladders within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber, and a process, The step of disposing a bladder cover over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the workpiece Including, steps; The step of independently expanding the plurality of inner bladders to selectively apply pressure to the workpiece within the tool chamber to form the part Including, The bladder sub-assembly includes a plurality of inlet tubes, each inlet tube of the plurality of inlet tubes extending from the inner bladder chamber of a respective inner bladder to the exterior of the tool, The bladder sub-assembly includes a first end cap disposed at a first end of the tool, the first end cap including a first end cap portion and a second end cap portion, The first end cap portion and the second end cap portion clamp the bladder cover and a first end of the inlet tube of each inner bladder therebetween to isolate the inner bladder chamber of each inner bladder within the tool chamber. A method.

15. A method of forming a part, The step of disposing a workpiece within a tool chamber of a tool, the tool including a first tool portion including a first tool surface and a second tool portion including a second tool surface facing the first tool surface, the first tool surface and the second tool surface defining the tool chamber, steps, The step of disposing a bladder sub-assembly within the tool chamber between the first tool surface and the second tool surface, The step of disposing a plurality of inner bladders within the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber, and a process, The step of disposing a bladder cover over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the workpiece Including, steps; selectively applying pressure to the workpiece within the tool chamber to form the component by independently expanding the plurality of inner bladders comprising the bladder cover comprises a flexible sheet each inner bladder comprises a flexible tube defining the inner bladder chamber the tool further comprises a first end cap disposed at a first end of the tool, the first end cap comprising a first end cap portion and a second end cap portion, the first end cap portion and the second end cap portion clamping a first end of the flexible sheet therebetween a method in which the first end cap portion and the second end cap portion clamp a first end of the flexible tube of each inner bladder therebetween to isolate the inner bladder chamber of the inner bladder within the tool chamber Claims 16 fixing the first tool portion relative to the second tool portion to form an airtight seal around the tool chamber prior to the step of expanding the plurality of inner bladders The method according to claim 14 or 15, further comprising Claims 17 The method according to any one of claims 14 to 16, wherein the step of expanding the plurality of inner bladders further comprises expanding the plurality of inner bladders with gas Claims 18 A method of forming a component, comprising placing a workpiece in a tool chamber of a tool, the tool comprising a first tool portion including a first tool surface and a second tool portion including a second tool surface facing the first tool surface, the first tool surface and the second tool surface defining the tool chamber placing a bladder subassembly in the tool chamber between the first tool surface and the second tool surface placing a plurality of inner bladders in the tool chamber, each inner bladder of the plurality of inner bladders including an inner bladder chamber placing a bladder cover over the plurality of inner bladders within the tool chamber to provide a barrier between the plurality of inner bladders and the workpiece including selectively applying pressure to the workpiece within the tool chamber to form the part, the step of independently expanding the plurality of inner bladders comprising the step of expanding the plurality of inner bladders further includes the step of expanding the plurality of inner bladders with a liquid, a method.

19. The method according to any one of claims 14 to 18, wherein the step of expanding the plurality of inner bladders further includes the step of expanding at least two of the plurality of inner bladders to different pressures.

20. The method according to any one of claims 14 to 19, wherein the step of expanding the plurality of inner bladders further includes the step of expanding at least two of the plurality of inner bladders at different times.

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