Tools for molded parts and methods of their manufacture

Abstract

Disclosed herein are, among other things, wind blade shell tools, segments of wind blade shell tools, and methods of manufacturing such tools and tool segments. In some embodiments, a tool or tool segment for manufacturing a molded part includes a tooling surface and a rigid frame. The frame may include a rigid frame surface having a near net shape for the tooling surface for the molded part. The tooling surface may be disposed within 120 mm of the frame surface. The frame surface may be disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface. The tooling surface can be formed by, for example, 3D printing. The tool may include an insulating layer, a heating layer, a print-surface layer, or a combination thereof.

Description

TOOLS FOR MOLDED PARTS AND METHODS OF THEIR MANUFACTURETECHNICAL FIELD

[0001] This disclosure relates generally to tools for molded parts and methods of their manufacture.BACKGROUND

[0002] Wind blade shells are formed using tools. Such tools must have precise shapes in order to form shells that are sufficiently aerodynamic for use in wind turbines. Such tools are typically formed using molding and machining. For example, a male plug is made using machining, on which a female mold shape is made, after which a production mold is made by joining the female mold shape within a steel frame. However, such molding and machining can be time consuming and expensive. There is a need for wind blade shell tools that can be manufactured at reduced cost and / or more quickly.SUMMARY

[0003] 3D printing (also known as additive manufacturing) is an attractive technology for forming tools for molded parts, such as wind blade shells, at least because it enables forming complex shapes (e g., with complex curvature) relatively simply. Large-scale, industrial 3D printing typically happens using extrusion-based methods, such as fused filament fabrication (FFF) or fused deposition modeling (FDM), whereby a print layer is built up from a flat print bed to have the desired topology. A tooling surface could be manufactured by 3D printing a print layer that terminates in a surface usable as a tooling surface for a tool for molded parts, such as a wind blade shell. Finishing (e.g., machining) may be used to further refine the tooling surface. To avoid unnecessary material use (and therefore expense), a hollow or semi-hollow support structure may be printed from a print base until a final continuous surface is printed in order to form a tooling surface. However, such printing may take a long period of time.

[0004] The present disclosure recognizes that providing a structured surface as a print base can greatly reduce the amount of time and material needed to form a tooling surface using 3D printing as compared to using a flat print base. Using a frame with a rigid frame surface that has a near net shape for a tooling surface for a desired part allows a reduced amount of 3Dprinted material to be used in order to achieve a tooling surface with a desired shape (i.e., the shape for the desired part). For example, a frame surface may have a near net shape such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to an intended tooling surface that will be printed on (e.g., directly on) the frame surface. Such near net shapes may reduce the amount of 3D print material needed by over 50% (e g., over 60%) and accordingly reduce the amount of time to print by over 50% (e.g., over 60%). Because of the use of a more complicated frame to manufacture a near net shape frame surface, there will be some additional cost for frame fabrication (e.g., steelwork). However, in general, the cost savings on material and print time can vastly outweigh the additional frame expenses (e.g., by a factor of 2, 3, 4, or more). Therefore, frames that include a frame surface having a near net shape for a tooling surface can be used to achieve reduced cost and / or faster fabrication of tools for molded parts, such as wind blade shells.

[0005] Moreover, forming an entire tool, or substantial majority of a tool, out of 3D print material may present tool quality issues. As one example, typical 3D print materials may have undesirably high coefficients of thermal expansion (CTEs) that reduce dimensional stability for the tool. Molding tools, such as for wind blade shells, often undergo relatively large temperature variations during part molding. Such temperature variations may impact final part quality if there is not sufficient dimensional stability in the tool, for example due to too much expansion and contraction during part fabrication. Therefore, the more 3D print material that is used in a tool, the more likely it is that the tool suffers from undesirable or detrimental effects. Using tools or tool segments as disclosed herein, a near net shape of a rigid frame surface of a rigid frame can provide and / or enhance dimensional stability to a tooling surface while also enabling reduced amount of 3D print material needed to form the tooling surface. In order to ensure a rigid frame surface actually imparts dimensional stability to a tooling surface, especially a tooling surface in a 3D print layer, a tool or tool segment may be constructed to have a tooling surface be disposed within 120 mm of (e.g., 120 mm or less from) a rigid frame surface. Smaller separation distance is preferable and is enabled using tools and tool segments disclosed herein.

[0006] In some aspects, the present disclosure is directed to a tool or tool segment for manufacturing a wind blade shell (e.g., having complex curvature). The tool or tool segment may include a tooling surface and a rigid frame, the frame including a rigid frame surface having a near net shape for the tooling surface for the wind blade shell. In some embodiments, theframe surface is disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface. The tooling surface may be disposed within 120 mm of the frame surface.

[0007] In some embodiments, the tooling surface is disposed within 80 mm (e.g., within 60 mm or within 40 mm) of the frame surface. In some embodiments, the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to the tooling surface. In some embodiments, the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm (e g., no more than 10 mm).

[0008] In some embodiments, the frame includes an insulating layer fastened to the frame, wherein the insulating layer includes an insulating layer surface that is the frame surface. In some embodiments, the insulating layer is fastened to the frame with fasteners disposed at a density of no fewer than 4 per m2(e g., no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2). In some embodiments, the tool or tool segment includes an insulating layer disposed on the frame surface between the frame surface and the tooling surface, the insulating layer having an insulating layer surface on a side opposite the frame surface, wherein the insulating layer surface also has a near net shape for the tooling surface. In some embodiments, the insulating layer surface is a machined surface (e.g., a CNC-machined surface).

[0009] In some embodiments, the near net shape of the insulating layer surface is shaped such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface. In some embodiments, the near net shape of the insulating layer surface is shaped such that the insulating layer surface is everywhere parallel to the tooling surface within 10 mm (e.g., within 5 mm, within 3 mm, within 2 mm, or within 1 mm).

[0010] In some embodiments, the insulating layer is a cellulose containing (e.g., woodbased) layer (e.g., includes or is made of wood). In some embodiments, the insulating layer is a foam layer (e.g., a rigid foam layer). In some embodiments, the insulating layer is a polymeric layer (e.g., rigid polymer foam). In some embodiments, the insulating layer is a foam layer. In some embodiments, the insulating layer is a rigid layer (e.g., rigid foam). In some embodiments, the insulating layer is a wood-based insulating layer (e.g., a wood layer), a rigid layer, a foam layer, a polymer layer, or a combination thereof (e.g., a rigid polymer foam layer or a rigid woodlayer). In some embodiments, the insulating layer is no more than 80 mm thick (e g., no more than 60 mm, no more than 50 mm, no more than 40 mm, or no more than 30 mm thick). In some embodiments, the insulating layer is fastened to the frame surface. In some embodiments, the insulating layer is fastened to the frame surface with fasteners disposed at a density of no fewer than 4 per m2(e.g., no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2).

[0011] In some embodiments, the tool or tool segment includes a heating layer disposed on (e.g., adhered to) the insulating layer surface between the insulating layer and the tooling surface. In some embodiments, the heating layer includes wire (e.g., resistive wire) (e.g., two or more discrete wires) (e.g., disposed in independently controllable heating zones in the heating layer). In some embodiments, the heating layer includes one or more heating elements each including (i) polymer (e.g., silicone) and (ii) at least a portion of the wire disposed in or on the polymer (e.g., encased in the polymer) (e.g., each of the one or more heating elements corresponding to one of the heating zones). In some embodiments, the heating layer is no more than 10 mm (e.g., no more than 8 mm, no more than 6 mm, no more than 5 mm, no more than 4 mm, or no more than 3 mm) thick.

[0012] In some embodiments, the tool or tool segment includes a print-surface film (e.g., a thermoplastic film) disposed in contact with (e.g., adhered to) the heating layer on a side opposite the insulating layer (e.g., wherein the film has a thickness of no more than 2 mm or no more than 1 mm). In some embodiments, a print layer (e.g., polymer print layer) including the tooling surface is disposed directly on the print-surface film.

[0013] In some embodiments, the tooling surface varies no more than 2 mm (e.g., no more than 1 mm or no more than 0.5 mm) from a predetermined wind blade shell shape. In some embodiments, the tooling surface has been formed using 3D printing [e.g., and subsequent machining (e.g., CNC machining)] (e.g., is a finished 3D-printed surface). In some embodiments, a (e.g., the) print layer (e.g., polymer print layer) includes the tooling surface. In some embodiments, the print layer is no more than 120 mm thick (e.g., no more than 100 mm, no more than 80 mm, no more than 60 mm, no more than 40 mm, or no more than 20 mm thick) before subsequent machining. In some embodiments, the print layer is no more than 60 mm thick (e g., no more than 50 mm, no more than 40 mm, no more than 30 mm, or no more than 20 mm thick) (e.g., before and after or only after subsequent machining). In some embodiments, noportion of the print layer is disposed more than 120 mm (e.g., more than 80 mm, more than 60 mm, or more than 40 mm) from the frame surface. In some embodiments, the tooling surface includes polymer including one or more toughening agents.

[0014] In some embodiments, the frame surface includes slats aligned with a span direction for the wind blade shell [e.g., in rows distributed chordwise (e.g., wherein more than one of the slats is disposed in each row)] [e.g., metal (e.g., steel or aluminum) slats]. In some embodiments, at least some of the slats have different lengths. In some embodiments, the frame surface includes a rigid mesh [e.g., a metal (e.g., steel or aluminum) mesh]. In some embodiments, the frame surface includes metal (e.g., steel or aluminum) (e.g., is made of steel or aluminum). In some embodiments, the frame includes contoured bulkheads [e.g., metal (e.g., steel or aluminum) bulkheads] that support the frame surface (e.g., to which the frame surface is fastened). In some embodiments, the contoured bulkheads are spatially distributed spanwise (e.g., evenly distributed) and aligned with a chord direction for the wind blade shell (e.g., wherein the slats are each attached to one or more of the bulkheads). In some embodiments, the frame surface provides distributed connection between the tooling surface and the frame surface.

[0015] In some embodiments, the frame surface, the insulating layer surface, the printsurface film, or a combination thereof provides a non-level base for the tooling surface and, over at least 85% (e.g., at least 90% or at least 95%) of a total area the frame surface, a maximum slope of the non-level base is 45°.

[0016] In some embodiments, the wind blade shell has a span of at least 50 m (e.g., at least 60 m, at least 70 m, at least 80 m, at least 90 m, at least 100 m, at least 110 m, or at least 120 m).

[0017] In some embodiments, the tool includes a plurality of the tool segments. In some embodiments, for each adjacent pair of the tool segments, the tooling surfaces of the adjacent tool segments are welded together with a plastic weld [e.g., with an amorphous or low- crystallinity (e.g., <20%) polymer]. The plastic weld may be disposed along adjacent edges of the tooling surfaces of the tool segments (e.g., wherein the plastic weld has a vacuum leakage of no more than 10 millibar over 30 minutes) [e.g., wherein the tooling surface includes an amorphous or low-crystallinity (e.g., <20%) polymer]. In some embodiments, the adjacent edges are beveled (e.g., have 60 degree bevels). In some embodiments, the adjacent edges have beensanded. In some embodiments, for each adjacent pair of the tool segments, the frames of the tool segments are fastened together.

[0018] In some aspects, the present disclosure is directed to a method of manufacturing a tool or tool segment for manufacturing a wind blade shell. The method may include providing a frame including a frame surface having a near net shape for a tooling surface for the wind blade shell. The method may include disposing the tooling surface on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface. In some embodiments, the tooling surface is disposed within 80 mm (e.g., than 60 mm or than 40 mm) of the frame surface. In some embodiments, the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to the tooling surface. In some embodiments, the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm (e.g., no more than 10 mm).

[0019] In some embodiments, the method includes fastening an insulating layer [e.g., a wood-based insulating layer, a rigid layer, a foam layer, a polymer layer, or a combination thereof (e.g., a rigid polymer foam layer)] to the frame surface. In some embodiments, the method includes providing an insulating layer, wherein a surface of the insulating layer is the frame surface. In some embodiments, the insulating layer has an insulating layer surface that has a near net shape for the tooling surface that is shaped such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface. In some embodiments, the method includes (e.g., subsequently) machining (e.g., with a CNC machine) the insulating layer to have an insulating layer surface that has a near net shape for the tooling surface such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface.

[0020] In some embodiments, the method includes disposing a heating layer on (e.g., adhering the heating layer to) the insulating layer surface, wherein the heating layer includes one or more individually controllable heating elements each including polymer (e.g., silicone) and wire disposed in or on the polymer (e.g., encased in the polymer). In some embodiments, the one or more heating elements is a plurality of heating elements and disposing the heating layer comprises individually disposing (e.g., adhering) the plurality of heating elements on the insulating layer surface.

[0021] In some embodiments, the method includes forming the tooling surface directly onto the heating layer by 3D printing a print layer (e.g., a polymer print layer) and subsequently machining the print layer. In some embodiments, the method includes disposing (e.g., adhering) a print-surface film (e.g., thermoplastic film) on the heating layer. In some embodiments, the method includes forming the tooling surface directly onto the print-surface film by 3D printing a print layer (e.g., a polymer print layer) and subsequently machining the print layer. In some embodiments, the forming includes incorporating one or more toughening agents into the tooling surface by the 3D printing [e.g., by using a print feedstock (e.g., filament) incorporating the one or more toughening agents]. In some embodiments, the method includes (i) applying heat with the heating layer to the print layer while the print layer is being printed and (ii) subsequently cooling the print layer to ambient temperature by ceasing application of heat from the heating layer (e.g., progressively). In some embodiments, the print layer is no more than 120 mm thick (e.g., no more than 100 mm, no more than 80 mm, no more than 60 mm, no more than 40 mm, or no more than 20 mm thick) before subsequent machining. In some embodiments, the print layer (e.g., polymer print layer) is no more than 60 mm thick (e.g., no more than 50 mm, no more than 40 mm, no more than 30 mm, or no more than 20 mm thick) (e.g., before and after or only after subsequent machining). In some embodiments, no portion of the print layer is disposed more than 120 mm (e.g., more than 80 mm, more than 60 mm, or more than 40 mm) from the frame surface after printing and subsequent machining.

[0022] In some embodiments, providing the frame includes forming the frame surface, wherein forming the frame surface includes (i) assembling a plurality of slats and / or (ii) molding a rigid mesh. In some embodiments, providing the frame includes (i) providing contoured bulkheads and (ii) disposing the frame surface on the contoured bulkheads [e.g., fastening the frame surface onto the contoured bulkheads (e.g., with bolts or by welding)].

[0023] In some embodiments, the method includes fastening the frame together with a frame of an adjacent tool segment. In some embodiments, the method includes plastic welding the tooling surface together with a tooling surface of an adjacent tool segment [e.g., with an amorphous or low-crystallinity (e.g., <20%) polymer] [e.g., wherein the tooling surface includes an amorphous or low-crystallinity (e.g., <20%) polymer]. In some embodiments, the method includes forming a bevel (e.g., a 60 degree bevel) at an edge of the tooling surface prior to theplastic welding. In some embodiments, the method includes sanding the bevel prior to the plastic welding.

[0024] The tool or tool segment may be any tool or tool segment disclosed herein.

[0025] In some aspects, the present disclosure is directed to a tool or tool segment for manufacturing a molded part (e.g., having complex curvature). The tool or tool segment may include a tooling surface and a rigid frame including a rigid frame surface having a near net shape for the tooling surface for the molded part. The frame surface may be disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface. The tooling surface may be disposed within 120 mm of the frame surface.

[0026] In some aspects, the present disclosure is directed to a method of manufacturing a tool or tool segment for manufacturing a molded part (e.g., wind blade shell). The method may include providing an incomplete portion of the tool or tool segment, wherein the incomplete portion of the tool or tool segment includes a heat source. The method may further include printing a print layer onto the incomplete portion of the tool or tool segment in order to complete (e.g., thereby completing) the tool or tool segment. The method may further include providing heat from the heat source to the print layer as the print layer is being printed. In some embodiments, the method includes, subsequent to providing the heat, cooling the print layer to ambient temperature by ceasing application of heat from the heat source (e.g., progressively).

[0027] In some embodiments, the incomplete portion of the tool or tool segment includes a heating layer and the heating layer includes the heat source. In some embodiments, the heat source is one or more independently controllable heating elements. In some embodiments, the incomplete portion of the tool or tool segment includes a frame including a frame surface having a near net shape for a tooling surface for the molded part (e.g., the wind blade shell) and the heating layer is disposed on the frame surface (e.g., directly on the frame surface). In some embodiments, the method includes forming a tooling surface for the molded part (e.g., the wind blade shell) in the print layer (e.g., by machining a print surface of the print layer) (e.g., wherein forming the tooling surface completes the tool or tool segment). In some embodiments, the incomplete portion of the tool or tool segment includes a frame including a frame surface having a near net shape for the tooling surface and the tooling surface is disposed on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface.

[0028] Any two or more of the features described in this specification, including in this summary section, may be combined to form implementations of the disclosure, whether specifically expressly described as a separate combination in this specification or not.

[0029] At least part of the methods, systems, and techniques described in this specification may be controlled by executing, on one or more processing devices, instructions that are stored on one or more non-transitory machine-readable storage media. Examples of non- transitory machine-readable storage media include read-only memory, an optical disk drive, memory disk drive, and random access memory. At least part of the methods, systems, and techniques described in this specification may be controlled using a computing system comprised of one or more processing devices and memory storing instructions that are executable by the one or more processing devices to perform various control operations.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present teachings described herein will be more fully understood from the following description of various illustrative embodiments, when read together with the accompanying drawings. It should be understood that the drawing described below is for illustration purposes only and is not intended to limit the scope of the present teachings in any way. The foregoing and other objects, aspects, features, and advantages of the disclosure will become more apparent and may be better understood by referring to the following description taken in conjunction with the accompanying drawings, in which:

[0031] FIG. 1 A is an exploded view of a wind blade shell tool, according to illustrative embodiments of the present disclosure;

[0032] FIG. IB is an unexploded view of the wind blade shell tool of FIG. 1 A;

[0033] FIG. 1C is an unexploded view of an alternative wind blade shell tool, according to illustrative embodiments of the present disclosure;

[0034] FIG. 2 is a flow diagram of a method of manufacturing a wind blade shell tool, according to illustrative embodiments of the present disclosure;

[0035] FIG. 3A is a plan view illustrating heating zones in a wind blade shell tool, according to illustrative embodiments of the present disclosure;

[0036] FIG. 3B is a perspective view illustrating heating zones in a wind blade shell tool, according to illustrative embodiments of the present disclosure;

[0037] FIG. 4 is a view of a frame for a wind blade shell tool, the frame having a near net shape, according to illustrative embodiments of the present disclosure;

[0038] FIG. 5 is a perspective view illustrating two tool segments that are joined, according to illustrative embodiments of the present disclosure;

[0039] FIGS. 6A-6B are illustrations of tool segments j oined by a plastic weld, according to illustrative embodiments of the present disclosure; and

[0040] FIGS. 7A-7D illustrate plastic welds that can be used to join tool segments, according to illustrative embodiments of the present disclosure.

[0041] Figures are not necessarily drawn to scale.DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0042] Disclosed herein are, inter alia, wind blade shell tools, segments of wind blade shell tools, and methods of manufacturing such tools and tool segments. Such tools can be used to manufacture wind blade shells of varying lengths and designs, ranging from, for example, 1 m to over 100 m in span. Wind blade shells are generally large scale, require high precision, and have complex shape (e.g., complex curvature). By using a rigid frame having a frame surface with a near net shape for a tooling surface for a wind blade shell, the rigid frame can simplify manufacturing time and / or cost for manufacturing wind blade shell tools that can satisfy the demanding criteria for the shells.

[0043] In some embodiments, a tool or tool segment for manufacturing a molded part includes a tooling surface and a rigid frame. The frame may include a rigid frame surface having a near net shape for the tooling surface for the molded part. The tooling surface may be disposed within 120 mm of (e.g., 120 mm or less from) the frame surface. The frame surface may be disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface. The tooling surface can be formed by, for example, 3D printing. The tool may include an insulating layer, a heating layer, a print-surface layer (e.g., constructed to facilitate 3D printing thereon), or a combination thereof. The insulating layer may be disposed directly on (e.g., fastened or otherwise affixed to) a frame surface. The heating layer may be disposed directly on an insulating layer or directly on a frame surface. The print-surface film may be disposed directly on an insulating layer, directly on the heating layer, or directly on the framesurface. The print layer may be disposed directly on the print-surface fdm, the heating layer, the insulating layer, or the frame surface.

[0044] Figs. 1A-1B illustrate an example of a wind blade shell tool 100. The view shown is exploded in Fig. 1 A and unexploded in Fig. IB. The tool 100 includes a frame 102. Frame 102 includes contoured bulkheads 102a and skeleton frame 102b. Contoured bulkheads 102a are aligned in a chord direction and are spatially separated in a span direction. Contoured bulkheads 102a are supported by skeleton frame 102b. Frame 102 also includes mesh 102c that has a frame surface 102d with a near net shape for tooling surface 110a. The tool 100 includes an insulating layer 104, which is fastened to frame surface 102d, for example using densely distributed bolts. The tool also includes heating layer 106, which is disposed directly on the insulating layer 104. The heating layer 106 may include or be made of polymer (e.g., silicone) with wires (e g., resistive wires) disposed throughout, for example encased in the polymer. The heating layer 106 may include one or more heating zones that are independently controllable (e.g., due to how they are wired and connected to a controller and / or switch). The tool 100 further includes a print-surface film 108, which is disposed directly on the heating layer 106, and a print layer 110 disposed directly on the print-surface film 108. The print-surface film 108 (e.g., thermoplastic film) may facilitate achieving a higher print fidelity for the print layer 110 than if print-surface film 108 was not used for example by providing favorable surface properties on which to print. The print layer 110 is printed (e g., 3D printed) directly on the print-surface film 108, for example using a large-scale extrusion based technique such as fused filament fabrication or fused deposition modeling. The print layer 110 may be machined after printing to achieve sufficient accuracy in size and shape for the tooling surface 110a. The tooling surface 110a is within 120 mm of (e.g., 120 mm or less from) the frame surface 102d. The near net shape of the frame surface 102d provides dimensional stability to the tooling surface 110a due to being sufficiently close (i.e., any intervening layers are sufficiently thin).

[0045] FIG. 1C illustrates a cross section of an alternative wind blade shell tool 100 where a frame 102 includes an insulating layer 104 fastened to the frame 102 with fasteners 112 to provide a rigid frame surface 102d. The insulating layer 104 has a near net shape for a tooling surface 110a. Fasteners 112 may be slightly recessed into the insulating layer 104 (as shown) in order to not topologically disrupt the frame surface 102d. A heating layer 106 is disposed directly on the insulating layer 104 and a print layer 110 is disposed directly on the heating layer106 (in some embodiments, there is a print-surface film disposed therebetween). The print layer 110 includes the tooling surface 110a. The tooling surface 110a may be disposed within 120 mm of the frame surface 102d of the insulating layer 104 while not being disposed within 120 mm of any underlying frame (e.g., bulkheads 101), for example due to a thickness of the print layer 110 and / or the insulating layer 104.

[0046] FIG. 2 is a flow diagram for an example of a method 200 for manufacturing a wind blade shell tool. In step 202, a frame that includes a frame surface having a near net shape for a tooling surface of a wind blade shell tool is provided. In optional step 204, an insulating layer is disposed on the frame surface. Disposing the insulating layer may include fastening or otherwise affixing the insulating layer to the frame (e.g., to a frame surface thereof). Disposing the insulating layer may further include machining the insulating layer, for example to form an insulating layer surface that has a near net shape for the tooling surface. In optional step 206, a heating layer is disposed, for example directly onto the insulating layer from optional step 204. In optional step 208, a print-surface film is disposed, for example directly onto the heating layer from optional step 206. In step 210, a tooling surface of the tool is disposed such that the tooling surface is within 120 mm of the frame surface. In some embodiments, disposing a tooling surface includes printing (e.g., 3D printing) a print layer. In some embodiments, disposing a tooling surface includes machining the print layer after the printing. Any one or combination of optional steps 204-208 may be included in embodiments of the method 200.

[0047] In some embodiments, heat is applied with a heating layer while a tooling surface is disposed (e.g., printed) over a frame surface (e.g., during a portion of the time over which the tooling surface is disposed over the frame surface). Such heating is especially useful when printing (e.g., 3D printing) a print layer as it may improve the quality of the print layer. For example, in some embodiments of extrusion-based 3D printing, such as fused fdament fabrication or fused deposition modeling, the filament is heated to a high temperature as it is extruded in order to be able to properly print the filament and form a print layer. Rapid cooling of the print layer as it is formed (e.g., if printed to a room temperature surface) may reduce quality due to strain or other undesirable forces that are introduced upon rapid cooling. In an extreme case, cracks or other deformities in the print layer could arise as a result of rapid cooling. Applying heat from a heating layer may mitigate or eliminate such undesirable forces. Moreover, heat from a heating layer is controllable so may be slowly reduced over time to avoidnegative effects of too rapid cooling. Because such a heating layer would already be present for use when molding wind blade shells (or other parts), there is no need for additional equipment or components in order to provide this additional heat to promote higher print layer integrity.

[0048] In some embodiments, a method includes applying heat with a heating layer to a print layer. For example, such heat can be applied while the print layer is being printed. In some embodiments, a method includes subsequently cooling a print layer to ambient temperature by ceasing application of heat from a heating layer. Application of heat may be ceased progressively. For example, heat from one or more heating elements may be reduced over time (e.g., slowly). Heat from different heating elements may be independently controlled , for example reduced at different rates, reduced at different times, or both, (e.g., shortly) after print layer printing. For example, different heating elements corresponding to different areas of a print layer corresponding to portions of a print layer surface with different curvatures may be controlled differently during heating and / or subsequent cooling.

[0049] In some embodiments, a method of manufacturing a tool or tool segment for manufacturing a molded part (e.g., wind blade shell) includes providing heat while a print layer is being printed. The heat may be provided by an incomplete portion of the tool or tool segment, for example a heat source in the incomplete portion of the tool or tool segment. In this way, the heat source in the incomplete portion of the tool or tool segment serves a dual purpose: it is included in the incomplete tool or tool segment for later using in forming molded parts and, while the tool is still being completed, it can be used to improve print layer quality. Thus, in some embodiments, a method includes forming a molded part using a tool or tool segment, wherein forming the molded part includes applying heat from a heat source that was used to form the tool or tool segment. In some embodiments, a method includes printing a print layer onto an incomplete portion of a tool or tool segment in order to complete (e.g., thereby completing) the tool or tool segment. Additional steps, such as finishing a print surface into a tooling surface, may be performed after the printing in order to complete the tool or tool segment. A method may include, subsequent to providing heat, cooling a print layer to ambient temperature by ceasing application of heat from a heat source in an incomplete portion of a tool or tool segment (e.g., progressively).

[0050] An incomplete portion of a tool or tool segment may include one or more elements (e.g., layers) of a tool or tool segment but be missing one or more elements (e.g.,layers) of a complete tool or tool segment and / or have one or more elements (e.g., layers) of the tool or tool segment be themselves incomplete (e.g., have an unfinished surface). For example, an incomplete portion of a tool or tool segment may be a tool or tool segment that is complete except that it is missing a print layer and the print layer may need to be finished in order to fully complete the tool or tool segment. An incomplete portion of the tool or tool segment may include a heating layer that includes a heat source, for example a heating layer disposed on a frame surface of a frame. A heat source may be one or more heating elements, for example one or more independently controllable heating elements. In some embodiments, forming a tooling surface in a print layer (e.g., by machining a print surface of the print layer) completes the tool or tool segment.

[0051] If a tooling surface is disposed too far from a rigid frame surface of a frame, then the rigid frame surface cannot impart dimensional stability to the tooling surface. Without dimensional stability, a tooling surface may be too prone to movement (e.g., expansion and contraction) during molding of parts, such as a wind blade shell to yield commercially acceptable parts. For example, in some embodiments, tooling surface movement of about + / - 1 mm or less is tolerable in any direction in response to operating temperature variation within tool operating range (e.g., from 20 °C to 100 °C, with many conventional tools typically operating at about 80 °C). Such minimal movement of a tooling surface during use of a tool would be dimensionally stable. In some embodiments, a tooling surface is disposed within 120 mm (e.g., within 80 mm, within 60 mm or within 40 mm) of a frame surface. Coefficient of thermal expansion (CTE) values of up to 100 ppm / °C are typical in 3D printed materials in directions transverse to the print (e.g., extrusion) direction. For example, estimated surface movement atop a 120 mm thick 3D print layer with a CTE of 100 ppm / °C (in the thickness direction) in response to a 60 °C temperature change is 60 °C * 100 ppm / °C * 120 mm, or 0.6% of 120 mm, or 0.72 mm. While thermal expansion & contraction are primary contributors to tooling surface movement during use, a smaller amount of additional movement may occur due to, for example, elastic deflections in response to weight of material (e.g., wind blade shell material) being molded and to any incidental forces applied to the tooling surface. Based on the amount of movement that would occur due to expansion and contraction for this exemplary 120 mm print layer, there is still a tolerance for movement arising from other sources. Therefore, even using a 120 mm print layeron a rigid frame surface having a near net shape, a tool could be dimensionally stable (e.g., within + / - 1 mm).

[0052] In some embodiments, a near net shape of a frame surface is shaped such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to a tooling surface. By reducing variation of the frame surface shape relative to the ultimately desired tooling surface shape, the amount of material that needs to be printed in a print layer (e.g., and subsequently machined) to form the tooling surface can be reduced. Using a rigid frame that includes a rigid frame surface having a near net shape for a tooling surface can drastically reduce the amount of material that needs to be printed to form the tooling surface. For example, one preliminary design of a 133 m2surface area wind blade shell tool would require about 18,000 kg of 3D printing material if the tool was constructed substantially entirely by 3D printing (e.g., by first printing a support structure and then a layer with the tooling surface), and 200 hours of machine time if deposited at 90 kg / hr. Rather than printing on a conventional flat bed and subsequently fastening the 18,000 kg filled thermoplastic insert to its required steel frame, using a frame that includes a frame surface with a near net shape would drastically reduce the amount of material and fabrication time. For example, a tool as disclosed herein for such a 133 m2tooling surface could reduce the amount of material needed in print layer to about 6,800 kg and accordingly reduce the print time by about 125 hours. There may be some increase in steel cost and fabrication costs for the rigid frame to fabricate the near net shaped frame surface that offset some of these savings. Such additional costs would typically be less than about $50,000.Nonetheless, net savings of well over $100,000 could be realized on print costs, vastly outweighing the $50,000 (or less) incremental cost of steelwork.

[0053] In some embodiments, a tool or tool segment (e.g., a frame thereof) includes an insulating layer. An insulating layer may be desirable to include in a tool in order to insulate a heating layer from a frame, especially where a frame is made of metal (e.g., steel) and therefore has a high thermal conductivity. Such insulation can ensure that the heating layer functions as intended when molding parts (e.g., wind blade shells); otherwise, significant heat intended to be applied to the part being molded may be lost to the frame.

[0054] In some embodiments, a frame includes an insulating layer (e.g., a wood layer or a rigid polymer foam layer) fastened to the frame, for example fastened to steelwork in the frame. In some embodiments, an insulating layer includes an insulating layer surface that is arigid frame surface. In some embodiments, an insulating layer is fastened to the frame with fasteners disposed at a density of no fewer than 4 per m2, for example no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2. The fasteners may be bolts or bolted clamps, for example. Thus, in some embodiments, an insulating layer may be considered to be a part of a frame with an insulating layer surface being a frame surface. Accordingly, in some embodiments, a tooling surface is disposed within 120 mm of an insulating layer surface that is also a frame surface. Moreover, in some embodiments, an insulating layer is more than 120 mm thick, for example an insulating may be at least 200 mm, or at least 300 mm (e.g., and no more than 1 m or no more than 500 mm) thick.

[0055] Even when an insulating layer is made from a material less rigid and less dimensionally stable than steel (e.g., a non-rigid material) (e g., wood), sufficiently fastening the insulating layer to a frame (e.g., with fasteners disposed at a density of no fewer than 4 per m2) may impart sufficient rigidity and dimensional stability to the insulating layer. For example, wood is naturally able to expand and contract significantly but fastening the wood to a rigid subframe (e.g., steelwork) at sufficient density effectively pins the wood to prevent it from expanding and contracting significantly. Such fastening may be used to provide sufficient rigidity to a thick slab of insulating layer (e.g., that is more than 120 mm thick) in order to provide an insulating layer surface that is a frame surface of a rigid frame having a near net shape for a tooling surface.

[0056] In some embodiments, a tool or tool segment includes an insulating layer disposed on a frame surface between the frame surface and a tooling surface. In some embodiments, an insulating layer has an insulating layer surface on a side opposite a frame surface, wherein the insulating layer surface also has a near net shape for a tooling surface (in addition to the frame surface having a near net shape). For example, an insulating layer may be fastened or otherwise affixed to a rigid mesh or slatted surface that defines a frame surface such that the insulating layer mimics a near net shape of the frame surface.

[0057] In some embodiments, an insulating layer surface is a machined surface (e.g., a CNC-machined surface). For example, a thick insulating layer is fastened to a frame (e.g., a rigid frame surface thereof) and then machined. Such machining may impart a near net shape to an insulating layer surface itself. Such a near net shape of an insulating surface may be closer toa desired tooling surface shape than a near net shape of a frame surface. For example, in some embodiments, a near net shape of an insulating layer surface is shaped such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to a tooling surface. In some embodiments, a near net shape of an insulating layer surface is shaped such that the insulating layer surface is everywhere parallel to a tooling surface within 10 mm (e.g., within 5 mm, within 3 mm, within 2 mm, or within 1 mm). In some embodiments, an insulating layer is constructed such that an insulating layer surface thereof has a near net shape for a tooling surface even without machining the insulating layer.

[0058] In some embodiments, an insulating layer is a cellulose containing (e.g., woodbased) layer (e.g., includes or is made of wood). Cellulose containing layers, such as wood or plywood, are inexpensive and easy to incorporate. An insulating layer may be a cellulose- containing layer. An insulating layer may be a wood-based layer. An insulating layer may be a wood layer. An insulating layer may be a foam layer (e.g., a rigid foam layer). An insulating layer may be a polymer layer. In some embodiments, an insulating layer is a polymeric layer (e.g., rigid polymer foam). An insulating layer may be a rigid layer. In some embodiments, an insulating layer is a wood-based insulating layer (e.g., a wood layer), a rigid layer, a foam layer, a polymer layer, or a combination thereof (e.g., a rigid polymer foam layer or a rigid wood layer). In some embodiments, an insulating layer is no more than 80 mm thick (e.g., no more than 60 mm, no more than 50 mm, no more than 40 mm, or no more than 30 mm thick). For example, in some embodiments, a thick slab of insulating material (e.g., between 40 and 60 mm thick) is fastened or otherwise affixed to a frame (e.g., a frame surface thereof) and is subsequently machined to be thinner, at least in some areas. In some embodiments, an insulating layer is fastened to a frame surface with fasteners disposed at a density of no fewer than 4 per m2(e.g., no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2).

[0059] In some embodiments, a tool or tool segment includes a heating layer. A heating layer may be disposed on (e.g., adhered to) (e.g., directly on) an insulating layer surface. A heating layer may be disposed between an insulating layer and a tooling surface. In some embodiments, a heating layer includes wire (e.g., resistive wire). A heating layer may include two or more discrete wires. Wire may be disposed into independently controllable heating zonesin the heating layer. For example, each heating zone may include one or more discrete wires. Independent heating zones are used in manufacture of certain complex parts, such as wind blade shells, because constraints of the parts (e.g., local curvature, part thickness, or local size) require different heating during molding to ensure proper part fabrication. It is common to use several heating zones to mold wind blade shells. FIGS. 3A-3B illustrate different heating zones used for exemplary wind blade shell shapes where different shading indicates the different zones. Independently controllable heating zones may have separate switches and / or controllers in order to impart the independent control, for example. In some embodiments, a heating layer includes one or more heating elements, each of the one or more heating elements including polymer (e.g., silicone) and wire (e.g., at least a portion of wire in the heating layer) disposed in or on the polymer (e.g., encased in the polymer). Each of the heating elements may correspond to one of one or more heating zones. A heating layer may be constructed by forming a single continuous layer and then selectively cutting the layer in order to account for complex curvature so that when the heating layer is disposed (e.g., adhered) (e.g., to an insulating layer) it forms a flat layer (e.g., conforms to the insulating layer surface without wrinkling). In some embodiments, a heating layer is no more than 10 mm (e.g., no more than 8 mm, no more than 6 mm, no more than 5 mm, no more than 4 mm, or no more than 3 mm) thick.

[0060] In some embodiments, a tool or tool segment includes a print-surface film (e.g., a thermoplastic film). A print-surface layer may be disposed in contact with (e.g., adhered to) a heating layer. A print-surface layer may be disposed in contact with a heating layer on a side opposite an insulating layer. A print-surface film may have a thickness of no more than 5 mm (e.g., no more than 4 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm). In some embodiments, a print layer (e.g., polymer print layer) is disposed directly on a print-surface film. In some embodiments, a print layer is disposed directly on a heating layer, for example where a heating layer has sufficient surface properties to accept a print layer thereon.

[0061] A print layer may include a tooling surface. For example, a print layer may be printed and then machined down to a final shape for a molded part (e.g., wind blade shell). In some embodiments, a tooling surface varies no more than 2 mm (e.g., no more than 1 mm or no more than 0.5 mm) from a predetermined wind blade shell shape. In some embodiments, a tooling surface is or has been formed using 3D printing, and optionally subsequent machining (e.g., CNC machining). A tooling surface may be a finished 3D-printed surface. In someembodiments, a print layer is no more than 120 mm thick (e.g., no more than 100 mm, no more than 80 mm, no more than 60 mm, no more than 50 mm, no more than 40 mm, no more than 30 mm, or no more than 20 mm thick). In some embodiments, an entire surface of a print layer is a tooling surface. A print layer may have an unfinished or finished (e.g., machined) surface. A print layer may be thinned by finishing, for example such that a surface of the print layer is more than 120 mm from a frame surface after printing and then finished (e.g., machined) so that the surface is a tooling surface disposed within 120 mm of the frame surface. A tooling surface may be formed without printing, for example by machining bulk material disposed on (e.g., directly on) without printing.

[0062] A print layer may be a polymer print layer. In some embodiments, a polymer used in a print layer has a flex modulus of at least 1 MPa (e.g., at least 2 MPa or at least 3 MPa) as defined by ASTM D790, at 21 °C. In some embodiments, a polymer used in a print layer has a CTE of no more than 40 ppm / °C (e.g., no more than 30 ppm / °C or no more than 25 ppm / °C). In some embodiments, a polymer used in a print layer has an anisotropy of no more than 3 : 1 (e.g., no more than 2.5: 1, no more than 2.1 : 1, or no more 2: 1) as defined in ASTM E831. In some embodiments, a polymer used in a print layer has a heat deflection temperature of at least 100 °C (e.g., at least 110 °C or at least 120 °C) as defined by ASTM D648, at a pressure in a range of 0.4 to 0.5 MPa. In some embodiments, a polymer used in a print layer has a combination of two or more of these properties. In some embodiments, a polymer used in a print layer is high impact polystyrene (HIPS) based (e g., is HIPS). In some embodiments, a polymer used in a print layer is styrene maleic anhydride (SMA) based (e.g., is SMA). A blend of HIPS and SMA based polymer (e.g., a blend of HIPS and SMA) may be used in a print layer. Such HIPS or SMA based polymers may include one or more fillers, such as, for example, one or more cellulose-based fillers and / or one or more toughening agents. Other polymers that may be used include polyethylene terephthalate glycol (PETG or PET-G), polylactic acide (PLA), acrylonitrile butadiene styrene (ABS), polystyrene, polypropylene, polycarbonate, poly sulfone (PSU), or polyethersulfone (PES). A tooling surface may include an amorphous or low- crystallinity (e.g., <20% crystalline) polymer.

[0063] In some embodiments, no portion of a print layer is disposed more than 120 mm (e.g., more than 80 mm, more than 60 mm, or more than 40 mm) from a frame surface. That is, in some embodiments, some portion of a print layer may be more than 120 mm from a rigidframe surface while no portion of a tooling surface defined in the print layer is more than 120 mm from the frame surface. For example, a small edge portion (e.g., accounting for no more than 10% of total volume or no more than 10% of total surface area of a surface that includes a tooling surface) of a print layer may be more than 120 mm (e.g., may be 125 or 130 mm from) a frame surface. For example, such area or volume may effectively form a lip around at least a portion of a perimeter of a tooling surface. In general it is preferred that no portion of the print layer is disposed more than 120 mm from a frame surface in addition to the frame surface being disposed within 120 mm of a tooling surface included in the print layer. In some embodiments, no portion of a print layer is disposed more than 150 mm (e.g., no more than 140 mm, no more than 130 mm, or no more than 125 mm) from a frame surface while a tooling surface of the print layer is within 120 mm of (e.g., 120 mm or less from) the frame surface.

[0064] In some embodiments, a tooling surface includes polymer including one or more toughening agents. One or more toughening agents may be used to improve print layer quality, for example by reducing susceptibility to cracking. One or more toughening agents may be incorporated into a polymer used for printing a print layer, for example during printing.

[0065] In some embodiments, a frame surface includes slats. Slats may be aligned with a span direction, for example for a wind blade shell. In some embodiments, slats are disposed rows distributed chordwise. For example, more than one of the slats may be disposed in each row. Slats may be metal (e.g., steel or aluminum) slats. In some embodiments, at least some of the slats have different lengths. In some embodiments, a frame surface includes a rigid mesh, for example a metal mesh, such as one made of steel or aluminum. FIG. 4 illustrates an example of a frame 102 that includes slats 102e defining frame surface 102d. The slats 102e are attached [e.g., fastened or otherwise affixed (e.g., welded)] to contoured bulkheads 102a that are aligned chordwise (in a chord direction) and spatially separated along a span direction (spanwise).

[0066] In some embodiments, a frame surface includes metal. The metal may be steel or aluminum. For example, a frame surface may be made of steel and / or aluminum. In some embodiments, a frame includes metal. The metal may be steel or aluminum. For example, a frame may be made of steel or aluminum. Steel and aluminum are suitably rigid materials (e.g., have suitable stiffness) (e.g., has dimensional stability) while still being sufficiently low cost to be commercially feasible and easy enough to process to form a frame (e.g., by cutting and welding).

[0067] In some embodiments, a frame includes contoured bulkheads, such as, for example metal (e.g., steel or aluminum) bulkheads. Contoured bulkheads may be used to support a frame surface. A frame surface may be fastened or otherwise affixed (e.g., welded) to contoured bulkheads of a frame. In some embodiments, contoured bulkheads are spatially distributed spanwise (e.g., evenly distributed) and aligned with a chord direction for the wind blade shell (e.g., wherein the slats are each attached to one or more of the bulkheads).

[0068] In some embodiments, a frame surface provides distributed connection between the tooling surface and the frame surface. In some embodiments, a frame surface, insulating layer surface, print-surface film, or a combination thereof provides a non-level base for a tooling surface and, over at least 85% (e.g., at least 90% or at least 95%) of a total area the frame surface, a maximum slope of the non-level base is 45°. Such maximum slope may mitigate or eliminate the possibility of slumping during printing. If a non-level base is too steep, excessive gravity-driven viscoelastic flow (slumping) could result. Slumping displacement would depend on melt temperature, viscosity and other material properties. Since in general a tooling surface will be finish machined, slumping of smaller magnitude than finish machining may be acceptable, though would still be preferably avoided. Because of the typical shape of a wind blade shell, there may be a small portion of a non-level base that exceeds the defined maximum slope (e.g., near a leading edge for the blade).

[0069] In some embodiments, a tool or tool segment is for a wind blade shell that has a span of at least 50 m (e g., at least 60 m, at least 70 m, at least 80 m, at least 90 m, at least 100 m, at least 110 m, or at least 120 m). In some embodiments, a tooling surface has a surface area of at least 1 m2, at least 2 m2, at least 4 m2, at least 5 m2, at least 10 m2, at least 20 m2, at least 25 m2, at least 50 m2, at least 75 m2, at least 100 m2, at least 125 m2, at least 150 m2at least 300 m2, or at least 500 m2. In some embodiments, a longest dimension (e.g., a span length) of a tooling surface is at least 0.5 m, at least 1 m, at least 2 m, at least 4 m, at least 5 m, at least 10 m, at least 20 m, at least 25 m, at least 50 m, at least 75 m, at least 100 m, at least 125 m, or at least 150 m. In some embodiments, a shortest dimension (e.g., a minimum chord length) of a tooling surface is at least 0.1 m, at least 0.2 m, at least 0.25 m, at least 0.5 m, at least 0.75 m, at least 1 m, at least 2 m, at least 5 m, at least 10 m, at least 20 m, at least 25 m, at least 50 m, at least 75 m, or at least 100 m.

[0070] In some embodiments, a tool includes a plurality of tool segments as disclosed herein. Tool segments may be joined together, for example fastened and / or welded (e.g., plastic welded) together. Frames of adjacent tool segments may be joined (e.g., fastened) together, for example in a fixed manner or using bushings that provide 1 degree of freedom movement (e.g., expansion) (e.g., spanwise). In some embodiments, for each adjacent pair of tool segments, tooling surfaces of the adjacent tool segments are welded together with a plastic weld. A plastic weld may be made with an amorphous or low-crystallinity (e.g., <20% crystalline) polymer disposed along adjacent edges of tooling surfaces of tool segments. In some embodiments, a plastic weld that joins two adjacent tool segments has a vacuum leakage of no more than 10 millibar over 30 minutes. In some embodiments, adjacent edges of print layers of adjacent tool segments that are joined are beveled (e.g., have 60 degree bevels or have bevels at an angle in a range of 15 degrees to 75 degrees or of 30 degrees to 60 degrees or of 45 degrees to 75 degrees). In some embodiments, adjacent edges of print layers of adjacent tool segments that are joined have been sanded prior to joining. In some embodiments, for each adjacent pair of tool segments, frames of the tool segments are fastened together. A plastic weld that joins adjacent tool segments (e.g., tooling surfaces thereof) may be aligned in a chord direction. A plastic weld that joins adjacent tool segments (e.g., tooling surfaces thereof) may be arranged chordwise. A same or different material may be used for the plastic weld as is used to form a tooling surface (e.g., is printed to form the tooling surface). FIG. 5 illustrates an example of two tool segments that are joined together, for example by a plastic weld.

[0071] Machining of a tooling surface may occur before, after, or both before and after welding tooling surfaces of tool segments together to form the tooling surface of the complete tool. For example, each tool segment may be a finished tool segment and segments are then joined together, including plastic welding, and then any plastic weld is further machined. In some embodiments, print layers are formed for each tool segment, then the tool segments are joined together, including plastic welding, (e.g., and fastening or otherwise affixing frames of adjacent segments together), and then a single machining operation is performed. In some embodiments, each plastic weld in a tool is sanded or otherwise smoothed without machining. For example, because generally about 0.5 mm - 1 mm precision with respect to a desired wind blade shell tool shape is acceptable, it may be sufficient to smooth plastic weld(s) by hand (e.g.,using a handheld tool) without detrimentally degrading the precision of the overall tooling surface.

[0072] FIGS. 6A-6B illustrate examples of a plastic weld joining two adjacent tool segments of a wind blade shell tool. In FIG. 6A, two tooling surfaces 110a of adjacent tool segments are joined by plastic weld 110b such that a continuous tooling surface is formed across the two tool segments. FIG. 6B illustrates a different view of two joined tool segments where adjacent tooling surfaces 110a are joined by a plastic weld 110b. Frames 102f-g of each adjacent tool segment are also joined together (e.g., fastened together). Each tooling surface 110a has a beveled edge. The beveled edges are adjacent and the plastic weld 110b joins the beveled edges together. The beveled edges may be sanded before joining by the plastic weld 110b in order to promote adherence. In some embodiments, when plastic welding, the welder preheats and fills the groove with some flash or squeeze-out on the opposite side of the joint, as shown in FIG. 6B.

[0073] FIGS. 7A-7D illustrate views of plastic welds that may be used to join tooling surfaces of different tool segments. FIG. 7A illustrates a plastic weld being formed. Surfaces 702a-b are being joined by plastic weld 704 using weld foot 706 through which material is applied to form the weld 704. FIG. 7B is a perspective view of how the plastic weld would look. Beveled edges of surfaces 702a-b are adjacent and meet at the bottom of the surfaces. In some embodiments, there may be a small gap therebetween instead. Plastic weld 704 fills in the empty volume otherwise defined by beveled edges. In some embodiments, it is preferable for tooling surfaces to be aligned and leveled with a gap of no more than 5 mm across the entire segment seam. FIGS. 7C-7D are photographs of actual plastic welds.

[0074] Amorphous and low-crystallinity polymers are easier to weld due to their random or low molecular organization. When heated beyond their glass transition temperature, amorphous polymers melt together at the molecular level. Semi-crystalline polymers, on the other hand, have highly ordered molecular structures that result in a sharp melting point instead of gradual softening, making them more challenging to weld. To weld thermoplastics, the materials must be heated above their glass transition temperature into their melt temperature range, which is a larger range for amorphous polymers than it is for semi-crystalline polymers.

[0075] Once a plastic weld is complete, a weld surface may be manually finished to remove extrusion bead fillet and create a cohesive tooling surface. Machining or a sliding router equipped with an end mill specialty jig can be used to achieve a smooth surface. Alternatively,an automatic hand planer or grinder can be used. After this step, the surface can be hand-sanded to further refine the finish.

[0076] Plastic welding will result in a permanent bond that would require routing or milling to reverse; thus, this step may preferably be conducted when molds are set in place in a production environment (e.g., at a final destination for a tool). Beveled edges of tooling surfaces can be prepared with, for example, a 60° V-groove router bit. This will bevel each surface with a full-thickness chamfer into which weld material will flow. Once beveled, tool segments should be fixed (e.g., to a production floor) and then aligned and adjusted as needed. Initial adjustment of tooling surfaces of tool segments should occur before welding to reduce stresses at weld seams. In some embodiments, once tool segments are set, adjacent tooling surfaces (e.g., beveled edges thereof) are lightly sanded (e.g., with 120 to 150-grit sandpaper) and then thoroughly cleaned to ensure they are clear of obstructions and debris. In some embodiments, at this point, a weld can be completed across the chord of the tooling segments ensuring the process parameters are proper for the material being welded. In some embodiments, after a weld has cooled for at least thirty minutes, it can be finished to meet the specification of a tooling surface. Generally, plastic welds should be fully cooled to ambient conditions before further processing.

[0077] A plastic weld may have a vacuum integrity of no more than a 10 mbar drop (e.g., no more than 8 mbar drop or no more than 6 mbar drop) over at least 30 min (e.g., at least 1 h). A tooling surface may include one or more plastic welds (e.g., that have been finished), for example where a tool is formed by joining multiple tooling segments. A tooling surface (e.g., that includes one or more plastic welds) may have a vacuum integrity of no more than a 10 mbar drop (e.g., no more than 8 mbar drop or no more than 6 mbar drop) over at least 30 min (e.g., at least 1 h). A print layer may have a vacuum integrity of no more than a 10 mbar drop (e.g., no more than 8 mbar drop or no more than 6 mbar drop) over at least 30 min (e.g., at least 1 h).

[0078] Multiple tool segments may be joined to define an overall tooling surface, for example, for a wind blade shell tool. For smaller (e.g., shorter) wind blade shells (or other parts), a contiguous tool can be made without the use of tool segments. For larger (e.g., longer) wind blade shells (or other parts), it may be impractical to manufacture a contiguous tool and therefore an approach that involves fabricating tool segments and then joining the tool segments may be preferred. For example, some wind blade shells are very large (e.g., have a span of over 50 m, over 60 m, over 70 m, over 80 m, over 90 m, or over 100 m). It may be impractical tofabricate and / or transport a contiguous tool for such a large wind blade shell. Tools or tool segments may be manufactured by a first company and transported to a second company that handles manufacture of wind blades (including molding shells using the tool). It is common, and indeed likely, for such transport to involve transport by truck. Appropriate trucks typically have a bed length of about 18 m. Therefore, for tools for larger parts, such as large wind blade shells, tool segments may be designed that are approximately 18 m in length. So, a large wind blade shell tool may include 5-7 tool segments j oined together, in some embodiments. Other transportation schemes (e.g., specialized trucks or non-truck means) may lend themselves to other tool segment sizes. In some embodiments, a tooling surface of a tool segment has a longest dimension of no more than 40 m, no more than 30 m, no more than 25 m, no more than 20 m, no more than 15 m, or no more than 10 m. In some embodiments, a tooling surface of a tool segment has a longest dimension of at least 1 m, at least 2 m, at least 5 m, or at least 10 m. In general, the largest feasible tool segment size is preferable in order to reduce the number of plastic welds or other means for joining tooling surfaces of the segments together to form a continuous tooling surface for the overall tool.

[0079] The foregoing description has focused on wind blade shell tools but systems, devices, and methods described herein may be also applied to tools for other molded parts. For example, benefits of frames having near net shapes may also be desirable for tools for other molded parts, especially large scale, high precision, and / or complex (e.g., having complex curvature) molded parts, examples of which include wind turbine blade spars, wind turbine nacelles, composite aircraft wing or fuselage skins, aircraft engine nacelles, marine hulls, automotive or rail car body panels, or composite beams (e.g. tub girders) for civil construction, or portions (e.g., segments) thereof. In some embodiments, a tool or tool segment for manufacturing a molded part includes a tooling surface and a rigid frame. The frame may include a rigid frame surface having a near net shape for the tooling surface for the molded part. The tooling surface may be disposed within 120 mm of the frame surface. The frame surface may be disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface. The tool or tool segment include one or more additional features as disclosed herein previously.

[0080] The foregoing disclosure taught various features of tools or tool segments. Where a feature was discussed in the context of a tool, such a feature may be present in a tool segmentas well. Where a feature was discussed in the context of a tool segment, such a feature may be present in a tool as well. That is, the absence of the phrase “tool or tool segment” should not be construed to limit the disclosure to only either tools or tool segments.

[0081] Without limitation to the foregoing description, the following is an enumerated list of non-limiting exemplary embodiments included in the present disclosure. Those of ordinary skill in the art will appreciate that one or more features discussed above may be included with or incorporated into any of the following numbered embodiments to form additional embodiments.1. A tool or tool segment for manufacturing a wind blade shell (e.g., having complex curvature), the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the wind blade shell, wherein the tooling surface is disposed within 120 mm of the frame surface.2. A tool or tool segment for manufacturing a wind blade shell (e.g., having complex curvature), the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the wind blade shell, wherein the frame surface is disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface.3. The tool or tool segment of embodiment 1 or embodiment 2, wherein the tooling surface is disposed within 80 mm (e.g., within 60 mm or within 40 mm) of the frame surface.4. The tool or tool segment of any one of the preceding embodiments, wherein the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to the tooling surface.5. The tool or tool segment of any one of the preceding embodiments, wherein the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm (e.g., no more than 10 mm).6. The tool or tool segment of any one of the preceding embodiments, wherein the frame comprises an insulating layer fastened to the frame, wherein the insulating layer comprises an insulating layer surface that is the frame surface.7. The tool or tool segment of embodiment 6, wherein the insulating layer is fastened to the frame with fasteners disposed at a density of no fewer than 4 per m2(e.g., no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2).8. The tool or tool segment of any one of embodiments 1-5, comprising an insulating layer disposed on the frame surface between the frame surface and the tooling surface, the insulating layer having an insulating layer surface on a side opposite the frame surface, wherein the insulating layer surface also has a near net shape for the tooling surface.9. The tool or tool segment of any one of embodiments 6-8, wherein the insulating layer surface is a machined surface (e.g., a CNC-machined surface).10. The tool or tool segment of any one of embodiments 6-9, wherein the near net shape of the insulating layer surface is shaped such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface.11. The tool or tool segment of any one of embodiments 6-10, wherein the near net shape of the insulating layer surface is shaped such that the insulating layer surface is everywhere parallel to the tooling surface within 10 mm (e.g., within 5 mm, within 3 mm, within 2 mm, or within 1 mm).12. The tool or tool segment of any one of embodiments 6-1 1, wherein the insulating layer is a cellulose containing (e.g., wood-based) layer (e.g., comprises or is made of wood) or a polymeric layer (e.g., a rigid polymer foam layer).13. The tool or tool segment of any one of embodiments 6-12, wherein the insulating layer is a rigid foam layer.14. The tool or tool segment of any one of embodiments 6-13, wherein the insulating layer is no more than 80 mm thick (e.g., no more than 60 mm, no more than 50 mm, no more than 40 mm, or no more than 30 mm thick).15. The tool or tool segment of any one of embodiments 8-14, wherein the insulating layer is fastened to the frame surface.16. The tool or tool segment of embodiment 15, wherein the insulating layer is fastened to the frame surface with fasteners disposed at a density of no fewer than 4 per m2(e.g., no fewer than 6 per m2, no fewer than 8 per m2, no fewer than 10 per m2, no fewer than 12 per m2, no fewer than 16 per m2, or no fewer than 20 per m2).17. The tool or tool segment of any one of embodiments 6-16, comprising a heating layer disposed on (e.g., adhered to) the insulating layer surface between the insulating layer and the tooling surface.18. The tool or tool segment of embodiment 17, wherein the heating layer comprises wire (e.g., resistive wire) (e.g., two or more discrete wires) (e.g., disposed in independently controllable heating zones in the heating layer).19. The tool or tool segment of embodiment 18, wherein the heating layer comprises one or more heating elements each comprising (i) polymer (e.g., silicone) and (ii) at least a portion of the wire disposed in or on the polymer (e.g., encased in the polymer) (e.g., each of the one or more heating elements corresponding to one of the heating zones).20. The tool or tool segment of any one of embodiments 17-19, wherein the heating layer is no more than 10 mm (e.g., no more than 8 mm, no more than 6 mm, no more than 5 mm, no more than 4 mm, or no more than 3 mm) thick.21. The tool or tool segment of any one of embodiments 17-20, comprising a print-surface film (e.g., a thermoplastic film) disposed in contact with (e.g., adhered to) the heating layer on a side opposite the insulating layer (e.g., wherein the film has a thickness of no more than 2 mm or no more than 1 mm).22. The tool or tool segment of embodiment 21, wherein a print layer (e.g., polymer print layer) comprising the tooling surface is disposed directly on the print-surface film.23. The tool or tool segment of any one of the preceding embodiments, wherein the tooling surface varies no more than 2 mm (e.g., no more than 1 mm or no more than 0.5 mm) from a predetermined wind blade shell shape.24. The tool or tool segment of embodiment 22 or embodiment 23, wherein the tooling surface has been formed using 3D printing [e.g., and subsequent machining (e.g., CNC machining)] (e.g., is a finished 3D-printed surface).25. The tool or tool segment of any one of the preceding embodiments, wherein a (e.g., the) print layer (e.g., polymer print layer) comprises the tooling surface.26. The tool or tool segment of embodiment 22 or embodiment 25, wherein the print layer is no more than 60 mm thick (e.g., no more than 50 mm, no more than 40 mm, no more than 30 mm, or no more than 20 mm thick) [e.g., has been machined down from a layer thickness of no more than 120 mm (e.g., no more than 100 mm, no more than 80 mm, no more than 60 mm, no more than 40 mm, or no more than 20 mm)].27. The tool or tool segment of embodiment 22, embodiment 25, or embodiment 26, wherein no portion of the print layer is disposed more than 120 mm (e.g., more than 80 mm, more than 60 mm, or more than 40 mm) from the frame surface.28. The tool or tool segment of any one of the preceding embodiments, wherein the tooling surface comprises polymer comprising one or more toughening agents.29. The tool or tool segment of any one of embodiments 1-5 and 8-28, wherein the frame surface comprises slats aligned with a span direction for the wind blade shell [e.g., in rows distributed chordwise (e.g., wherein more than one of the slats is disposed in each row)] [e.g., metal (e.g., steel or aluminum) slats],30. The tool or tool segment of embodiment 29, wherein at least some of the slats have different lengths.31. The tool or tool segment of any one of the preceding embodiments, wherein the frame surface comprises a rigid mesh [e.g., a metal (e.g., steel or aluminum) mesh],32. The tool or tool segment of any one of the preceding embodiments, wherein the frame surface comprises metal (e.g., steel or aluminum) (e.g., is made of steel or aluminum).33. The tool or tool segment of any one of the preceding embodiments, wherein the frame comprises contoured bulkheads [e.g., metal (e.g., steel or aluminum) bulkheads] that support the frame surface (e.g., to which the frame surface is fastened).34. The tool or tool segment of embodiment 33, wherein the contoured bulkheads are spatially distributed spanwise (e.g., evenly distributed) and aligned with a chord direction for the wind blade shell (e.g., wherein the slats are each attached to one or more of the bulkheads).35. The tool or tool segment of any one of the preceding embodiments, wherein the frame surface provides distributed connection between the tooling surface and the frame surface.36. The tool or tool segment of any one of the preceding embodiments, wherein the frame surface, the insulating layer surface, the print-surface film, or a combination thereof provides a non-level base for the tooling surface and, over at least 85% (e.g., at least 90% or at least 95%) of a total area the frame surface, a maximum slope of the non-level base is 45°.37. The tool or tool segment of any one of the preceding embodiments, wherein the wind blade shell has a span of at least 50 m (e g., at least 60 m, at least 70 m, at least 80 m, at least 90 m, at least 100 m, at least 110 m, or at least 120 m).38. A tool comprising a plurality of tool segments according to any one of the preceding embodiments, wherein for each adjacent pair of the tool segments, the tooling surfaces of the adjacent tool segments are welded together with a plastic weld [e.g., with an amorphous or low- crystallinity (e.g., <20%) polymer] disposed along adjacent edges of the tooling surfaces of the tool segments (e.g., wherein the plastic weld has a vacuum leakage of no more than 10 millibar over 30 minutes) [e.g., wherein the tooling surface comprises an amorphous or low-crystallinity (e.g., <20%) polymer],39. The tool of embodiment 38, wherein the adjacent edges are beveled (e.g., have 60 degree bevels).40. The tool of embodiment 38 or embodiment 39, wherein the adjacent edges have been sanded.41. The tool of any one of embodiments 38-40, wherein, for each adjacent pair of the tool segments, the frames of the tool segments are fastened together.42. A method of manufacturing a tool or tool segment for manufacturing a wind blade shell, the method comprising: providing a frame comprising a frame surface having a near net shape for a tooling surface for the wind blade shell; anddisposing the tooling surface on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface.43. The method of embodiment 42, wherein the tooling surface is disposed within 80 mm (e.g., than 60 mm or than 40 mm) of the frame surface.44. The method of embodiment 42 or embodiment 43, wherein the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm (e.g., no more than 10 mm) relative to the tooling surface.45. The method of any of embodiments 42-44, wherein the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm (e.g., no more than 10 mm).46. The method of any one of embodiments 42-45, comprising fastening an insulating layer (e.g., a wood-based insulating layer or a rigid polymer foam layer) to the frame surface.47. The method of embodiment 46, wherein the insulating layer has an insulating layer surface that has a near net shape for the tooling surface that is shaped such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface.48. The method of embodiment 46 or embodiment 47, comprising (e.g., subsequently) machining (e.g., with a CNC machine) the insulating layer to have an insulating layer surface that has a near net shape for the tooling surface such that the insulating layer surface varies no more than 10 mm (e.g., no more than 5 mm, no more than 3 mm, no more than 2 mm, or no more than 1 mm) relative to the tooling surface.49. The method of embodiment 47 or embodiment 48, comprising disposing a heating layer on (e.g., adhering the heating layer to) the insulating layer surface, wherein the heating layercomprises one or more individually controllable heating elements each comprising polymer (e.g., silicone) and wire disposed in or on the polymer (e.g., encased in the polymer).50. The method of embodiment 49, wherein the one or more heating elements is a plurality of heating elements and disposing the heating layer comprises individually disposing (e.g., adhering) the plurality of heating elements on the insulating layer surface.51. The method of embodiment 49 or embodiment 50, comprising forming the tooling surface directly onto the heating layer by 3D printing a print layer (e.g., a polymer print layer) and subsequently machining the print layer.52. The method of embodiment 49 or embodiment 50, comprising disposing (e.g., adhering) a print-surface film (e.g., thermoplastic film) on the heating layer.53. The method of embodiment 52, comprising forming the tooling surface directly onto the print-surface film by 3D printing a print layer (e.g., a polymer print layer) and subsequently machining the print layer.54. The method of embodiment 51 or embodiment 53, wherein the forming comprises incorporating one or more toughening agents into the tooling surface by the 3D printing [e.g., by using a print feedstock (e.g., filament) incorporating the one or more toughening agents],55. The method of embodiment 51, embodiment 53, or embodiment 54, comprising (i) applying heat with the heating layer to the print layer while the print layer is being printed and (ii) subsequently cooling the print layer to ambient temperature by ceasing application of heat from the heating layer (e.g., progressively).56. The method of embodiment 51, embodiment 53, embodiment 54, or embodiment 55, wherein the print layer is no more than 120 mm thick (e.g., no more than 100 mm, no more than 80 mm, no more than 60 mm, no more than 40 mm, or no more than 20 mm thick) before subsequent machining.57. The method of any one of embodiment 51 and embodiment 53-56, wherein the print layer (e.g., polymer print layer) is no more than 60 mm thick (e.g., no more than 50 mm, no more than 40 mm, no more than 30 mm, or no more than 20 mm thick) (e.g., before and after or only after subsequent machining).58. The method of any one of embodiments 51 and 53-57, wherein no portion of the print layer is disposed more than 120 mm (e.g., more than 80 mm, more than 60 mm, or more than 40 mm) from the frame surface after printing and subsequent machining.59. The method of any one of embodiments 42-58, wherein providing the frame comprises forming the frame surface, wherein forming the frame surface comprises (i) assembling a plurality of slats and / or (ii) molding a rigid mesh.60. The method of embodiment 59, wherein providing the frame comprises (i) providing contoured bulkheads and (ii) disposing the frame surface on the contoured bulkheads [e.g., fastening the frame surface onto the contoured bulkheads (e.g., with bolts or by welding)].61. The method of any one of embodiments 42-60, comprising fastening the frame together with a frame of an adj acent tool segment.62. The method of any one of embodiments 42-61, comprising plastic welding the tooling surface together with a tooling surface of an adjacent tool segment [e.g., with an amorphous or low-crystallinity (e.g., <20%) polymer] [e g., wherein the tooling surface comprises an amorphous or low-crystallinity (e.g., <20%) polymer],63. The method of embodiment 62, comprising forming a bevel (e.g., a 60 degree bevel) at an edge of the tooling surface prior to the plastic welding.64. The method of embodiment 63, comprising sanding the bevel prior to the plastic welding.65. The method of any one of embodiments 42-64, wherein the tool or tool segment is any one of embodiments 1-41.66. A tool or tool segment for manufacturing a molded part (e.g., having complex curvature), the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the molded part, wherein the tooling surface is disposed within 120 mm of the frame surface.67. A tool or tool segment for manufacturing a molded part (e.g., having complex curvature), the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the molded part, wherein the frame surface is disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface.68. A method of manufacturing a tool or tool segment for manufacturing a molded part (e.g., wind blade shell), the method comprising: providing an incomplete portion of the tool or tool segment, wherein the incomplete portion of the tool or tool segment comprises a heat source; printing a print layer onto the incomplete portion of the tool or tool segment in order to complete (e.g., thereby completing) the tool or tool segment; and providing heat from the heat source to the print layer as the print layer is being printed.69. The method of embodiment 68, comprising, subsequent to providing the heat, cooling the print layer to ambient temperature by ceasing application of heat from the heat source (e.g., progressively).70. The method of embodiment 68 or embodiment 69, wherein the incomplete portion of the tool or tool segment comprises a heating layer and the heating layer comprises the heat source.71. The method of embodiment 70, wherein the heat source is one or more independently controllable heating elements.72. The method of embodiment 70 or embodiment 71, wherein the incomplete portion of the tool or tool segment comprises a frame comprising a frame surface having a near net shape for a tooling surface for the molded part (e.g., the wind blade shell) and the heating layer is disposed on the frame surface (e.g., directly on the frame surface).73. The method of any one of embodiments 68-72, comprising forming a tooling surface for the molded part (e.g., the wind blade shell) in the print layer (e.g., by machining a print surface of the print layer) (e.g., wherein forming the tooling surface completes the tool or tool segment).74. The method of embodiment 73, wherein the incomplete portion of the tool or tool segment comprises a frame comprising a frame surface having a near net shape for the tooling surface and the tooling surface is disposed on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface.75. The method of any one of embodiments 68-74, comprising forming the molded part using the tool or tool segment, wherein forming the molded part comprises applying heat from the heat source.

[0082] It is contemplated that systems, devices, methods, and processes of the disclosure encompass variations and adaptations developed using information from the embodiments described herein. Adaptation and / or modification of the systems, devices, methods, and processes described herein may be performed by those of ordinary skill in the relevant art.

[0083] Throughout the description, where articles, devices, and systems are described as having, including, or comprising specific components, or where processes and methods are described as having, including, or comprising specific steps, it is contemplated that, additionally, there are articles, devices, and systems according to certain embodiments of the present disclosure that consist essentially of, or consist of, the recited components, and that there areprocesses and methods according to certain embodiments of the present disclosure that consist essentially of, or consist of, the recited processing steps.

[0084] It should be understood that the order of steps or order for performing certain action is immaterial so long as operability is not lost. Moreover, two or more steps or actions may be conducted simultaneously. As is understood by those skilled in the art, the terms “over”, “under”, “above”, “below”, “beneath”, and “on” are relative terms and can be interchanged in reference to different orientations of the layers, elements, and substrates included in the present disclosure. For example, a first layer on a second layer, in some embodiments means a first layer directly on and in contact with a second layer. In other embodiments, a first layer on a second layer can include another layer therebetween.

[0085] In this application, unless otherwise clear from context or otherwise explicitly stated, (i) the term “a” may be understood to mean “at least one”; (ii) the term “or” may be understood to mean “and / or”; (iii) the terms “comprising” and “including” may be understood to encompass itemized components or steps whether presented by themselves or together with one or more additional components or steps; (iv) the terms “about” and “approximately” may be understood to permit standard variation as would be understood by those of ordinary skill in the relevant art; and (v) where ranges are provided, endpoints are included. In certain embodiments, the term "approximately" or "about" refers to a range of values that fall within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction (greater than or less than) of the stated reference value unless otherwise stated or otherwise evident from the context (except where such number would exceed 100% of a possible value).

[0086] Certain embodiments of the present disclosure were described above. It is, however, expressly noted that the present disclosure is not limited to those embodiments, but rather the intention is that additions and modifications to what was expressly described in the present disclosure are also included within the scope of the disclosure. Moreover, it is to be understood that the features of the various embodiments described in the present disclosure were not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations were not made express, without departing from the spirit and scope of the disclosure. The disclosure has been described in detail with particular reference tocertain embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the claimed invention.

Claims

What is claimed is:

1. A tool or tool segment for manufacturing a wind blade shell, the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the wind blade shell, wherein the tooling surface is disposed within 120 mm of the frame surface.

2. A tool or tool segment for manufacturing a wind blade shell, the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the wind blade shell, wherein the frame surface is disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface.

3. The tool or tool segment of claim 1 or claim 2, wherein the tooling surface is disposed within 80 mm of the frame surface.

4. The tool or tool segment of claim 1 or claim 2, wherein the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm relative to the tooling surface.

5. The tool or tool segment of claim 1 or claim 2, wherein the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm.

6. The tool or tool segment of claim 1 or claim 2, wherein the frame comprises an insulating layer fastened to the frame, wherein the insulating layer comprises an insulating layer surface that is the frame surface.

7. The tool or tool segment of claim 6, wherein the insulating layer is fastened to the frame with fasteners disposed at a density of no fewer than 4 per m2.

8. The tool or tool segment of claim 1 or 2, comprising an insulating layer disposed on the frame surface between the frame surface and the tooling surface, the insulating layer having an insulating layer surface on a side opposite the frame surface, wherein the insulating layer surface also has a near net shape for the tooling surface.

9. The tool or tool segment of claim 6, wherein the insulating layer surface is a machined surface.

10. The tool or tool segment of claim 6, wherein the near net shape of the insulating layer surface is shaped such that the insulating layer surface varies no more than 10 mm relative to the tooling surface.

11. The tool or tool segment of claim 6, wherein the near net shape of the insulating layer surface is shaped such that the insulating layer surface is everywhere parallel to the tooling surface within 10 mm.

12. The tool or tool segment of claim 6, wherein the insulating layer is a polymeric or a cellulose containing layer.

13. The tool or tool segment of claim 6, wherein the insulating layer is a rigid foam layer.

14. The tool or tool segment of claim 6, wherein the insulating layer is no more than 80 mm thick.

15. The tool or tool segment of claim 8, wherein the insulating layer is fastened to the frame surface.

16. The tool or tool segment of claim 15, wherein the insulating layer is fastened to the frame surface with fasteners disposed at a density of no fewer than 4 per m2.

17. The tool or tool segment of claim 6, comprising a heating layer disposed on the insulating layer surface between the insulating layer and the tooling surface.

18. The tool or tool segment of claim 17, wherein the heating layer comprises wire.

19. The tool or tool segment of claim 18, wherein the heating layer comprises one or more heating elements each comprising (i) polymer and (ii) at least a portion of the wire disposed in or on the polymer.

20. The tool or tool segment of claim 17, wherein the heating layer is no more than 10 mm thick.

21. The tool or tool segment of claim 17, comprising a print-surface film disposed in contact with the heating layer on a side opposite the insulating layer.

22. The tool or tool segment of claim 21, wherein a print layer comprising the tooling surface is disposed directly on the print-surface film.

23. The tool or tool segment of claim 22, wherein the tooling surface varies no more than 2 mm from a predetermined wind blade shell shape.

24. The tool or tool segment of claim 22 or claim 23, wherein the tooling surface has been formed using 3D printing.

25. The tool or tool segment of claim 21, wherein a print layer comprises the tooling surface.

26. The tool or tool segment of claim 22 or claim 25, wherein the print layer is no more than60 mm thick.

27. The tool or tool segment of claim 22 or claim 25, wherein no portion of the print layer is disposed more than 120 mm from the frame surface.

28. The tool or tool segment of claim 1 or claim 2, wherein the tooling surface comprises polymer comprising one or more toughening agents.

29. The tool or tool segment of claim 1 or claim 2, wherein the frame surface comprises slats aligned with a span direction for the wind blade shell.

30. The tool or tool segment of claim 29, wherein at least some of the slats have different lengths.

31. The tool or tool segment of claim 1 or claim 2, wherein the frame surface comprises a rigid mesh.

32. The tool or tool segment of claim 1 or claim 2, wherein the frame surface comprises metal.

33. The tool or tool segment of claim 1 or claim 2, wherein the frame comprises contoured bulkheads.

34. The tool or tool segment of claim 33, wherein the contoured bulkheads are spatially distributed spanwise and aligned with a chord direction for the wind blade shell.

35. The tool or tool segment of claim 1 or claim 2, wherein the frame surface provides distributed connection between the tooling surface and the frame surface.

36. The tool or tool segment of claim 1 or claim 2, wherein the frame surface, the insulating layer surface, the print-surface film, or a combination thereof provides a non-level base for thetooling surface and, over at least 85% of a total area the frame surface, a maximum slope of the non-level base is 45°.

37. The tool or tool segment of claim 1 or claim 2, wherein the wind blade shell has a span of at least 50 m.

38. A tool comprising a plurality of tool segments according to any one of the preceding claims, wherein for each adjacent pair of the tool segments, the tooling surfaces of the adjacent tool segments are welded together with a plastic weld disposed along adjacent edges of the tooling surfaces of the tool segments.

39. The tool of claim 38, wherein the adjacent edges are beveled.

40. The tool of claim 38, wherein the adjacent edges have been sanded.

41. The tool of claim 38, wherein, for each adjacent pair of the tool segments, the frames of the tool segments are fastened together.

42. A method of manufacturing a tool or tool segment for manufacturing a wind blade shell, the method comprising: providing a frame comprising a frame surface having a near net shape for a tooling surface for the wind blade shell; and disposing the tooling surface on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface.

43. The method of claim 42, wherein the tooling surface is disposed within 80 mm of the frame surface.

44. The method of claim 42, wherein the near net shape of the frame surface is shaped such that the frame surface varies no more than 20 mm relative to the tooling surface.

45. The method of claim 42, wherein the near net shape of the frame surface is shaped such that the frame surface is everywhere parallel to the tooling surface within 20 mm.

46. The method of claim 42, comprising fastening an insulating layer to the frame surface.

47. The method of claim 46, wherein the insulating layer has an insulating layer surface that has a near net shape for the tooling surface that is shaped such that the insulating layer surface varies no more than 10 mm relative to the tooling surface.

48. The method of claim 46 or claim 47, comprising machining the insulating layer to have an insulating layer surface that has a near net shape for the tooling surface such that the insulating layer surface varies no more than 10 mm relative to the tooling surface.

49. The method of claim 47, comprising disposing a heating layer on the insulating layer surface, wherein the heating layer comprises one or more individually controllable heating elements each comprising polymer and wire disposed in or on the polymer.

50. The method of claim 49, wherein the one or more heating elements is a plurality of heating elements and disposing the heating layer comprises individually disposing the plurality of heating elements on the insulating layer surface.

51. The method of claim 49, comprising forming the tooling surface directly onto the heating layer by 3D printing a print layer and subsequently machining the print layer.

52. The method of claim 49, comprising disposing a print-surface fdm on the heating layer.

53. The method of claim 52, comprising forming the tooling surface directly onto the printsurface film by 3D printing a print layer and subsequently machining the print layer.

54. The method of claim 51 or claim 53, wherein the forming comprises incorporating one or more toughening agents into the tooling surface by the 3D printing.

55. The method of claim 51 or claim 53, comprising (i) applying heat with the heating layer to the print layer while the print layer is being printed and (ii) subsequently cooling the print layer to ambient temperature by ceasing application of heat from the heating layer.

56. The method of claim 51 or claim 53, wherein the print layer is no more than 120 mm thick before subsequent machining.

57. The method of claim 51, wherein the print layer is no more than 60 mm thick.

58. The method of claim 51, wherein no portion of the print layer is disposed more than 120 mm from the frame surface after printing and subsequent machining.

59. The method of claim 42, wherein providing the frame comprises forming the frame surface, wherein forming the frame surface comprises (i) assembling a plurality of slats and / or (ii) molding a rigid mesh.

60. The method of claim 59, wherein providing the frame comprises (i) providing contoured bulkheads and (ii) disposing the frame surface on the contoured bulkheads.

61. The method of claim 42, comprising fastening the frame together with a frame of an adjacent tool segment.

62. The method of claim 42, comprising plastic welding the tooling surface together with a tooling surface of an adjacent tool segment.

63. The method of claim 62, comprising forming a bevel at an edge of the tooling surface prior to the plastic welding.

64. The method of claim 63, comprising sanding the bevel prior to the plastic welding.

65. The method of claim 42, wherein the tool or tool segment is any one of claims 1 -40.

66. A tool or tool segment for manufacturing a molded part, the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the molded part, wherein the tooling surface is disposed within 120 mm of the frame surface.

67. A tool or tool segment for manufacturing a molded part, the tool or tool segment comprising: a tooling surface; and a rigid frame, the frame comprising a rigid frame surface having a near net shape for the tooling surface for the molded part, wherein the frame surface is disposed sufficiently close to the tooling surface to provide dimensional stability to the tooling surface.

68. A method of manufacturing a tool or tool segment for manufacturing a molded part, the method comprising: providing an incomplete portion of the tool or tool segment, wherein the incomplete portion of the tool or tool segment comprises a heat source; printing a print layer onto the incomplete portion of the tool or tool segment in order to complete the tool or tool segment; and providing heat from the heat source to the print layer as the print layer is being printed.

69. The method of claim 68, comprising, subsequent to providing the heat, cooling the print layer to ambient temperature by ceasing application of heat from the heat source.

70. The method of claim 68 or claim 69, wherein the incomplete portion of the tool or tool segment comprises a heating layer and the heating layer comprises the heat source.71 . The method of claim 70, wherein the heat source is one or more independently controllable heating elements.

72. The method of claim 70, wherein the incomplete portion of the tool or tool segment comprises a frame comprising a frame surface having a near net shape for a tooling surface for the molded part and the heating layer is disposed on the frame surface.

73. The method of claim 68, comprising forming a tooling surface for the molded part in the print layer.

74. The method of claim 73, wherein the incomplete portion of the tool or tool segment comprises a frame comprising a frame surface having a near net shape for the tooling surface and the tooling surface is disposed on the frame surface such that the tooling surface is disposed within 120 mm of the frame surface.

75. The method of claim 68, comprising forming the molded part using the tool or tool segment, wherein forming the molded part comprises applying heat from the heat source.

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