Additive Manufacturing Mold for Composite Curing
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Solution Overview
Problem
The production of composite parts with complex geometries is costly and time-consuming, especially in sectors like aerospace and automotive, where traditional tooling molds and multiple curing steps are required.
Innovation Solution
A production system utilizing a mold produced by additive manufacturing, combined with resin-impregnated fabrics, a vacuum bag, and an autoclave for curing, which allows for single-step curing and efficient production of composite parts with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tooling molds are used for composite parts with complex geometry, then the parts can be produced with closed and complex geometry, but the production becomes costly and time-consuming
Solution Approach 1:
The patent employs a disposable mold made from inexpensive materials that can be easily discarded after use. This mold is created using additive manufacturing techniques, allowing for rapid production and elimination of the need for expensive, complex tooling. The disposable nature of the mold eliminates tooling costs and reduces production time significantly.
Solution Approach 2:
The patent utilizes additive manufacturing parameters to create complex geometries that would be impossible with traditional subtractive or form-molding methods. By controlling layer thickness, infill patterns, and material deposition parameters, the system achieves precise complex shapes without requiring expensive tooling.
2Reliability
If multiple curing steps are used for composite parts, then the parts can be produced with traditional methods, but the production process becomes more complex and time-consuming
Solution Approach 1:
The patent combines multiple curing operations into a single integrated curing step. The mold design incorporates features that allow simultaneous curing of multiple composite layers in one operation, eliminating the need for separate curing steps for each layer or part. This reduces process complexity while maintaining production reliability.
Solution Approach 2:
The mold is pre-designed with integrated curing chambers and heating elements that enable all curing operations to be performed simultaneously in a single step. The preliminary configuration of the mold allows multiple curing operations to be merged before the actual curing process begins.
3Productivity
If additive manufacturing is used for mold production, then tooling costs and production time are reduced, but the mold may not be able to withstand high autoclave pressures
Solution Approach 1:
The patent uses composite materials in the mold construction, combining additive manufactured structural components with reinforcement elements. This creates a mold that maintains the cost and time advantages of additive manufacturing while achieving the mechanical strength required to withstand high autoclave pressures during the curing process.
Solution Approach 2:
The mold is designed as a segmented structure with strategic reinforcement at high-stress areas. The additive manufactured base structure is complemented by localized reinforcement elements that provide pressure resistance where needed while maintaining overall lightweight construction and cost-effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system significantly reduces tooling costs, design labor, and production time while enabling the production of composite parts with complex geometries in a single curing step, and it can withstand higher autoclave pressures.
Implementation Method 1
a vacuum bag placed on the mold so as to cover the outer surface of the mold on which the layer of prepregs is located, wherein the vacuum bag allows the air in the preform/fabrics to be removed at least partially, and allows evacuation of the air and/or resin in the fabric and/or the air between the vacuum bag and the mold
Implementation Method 2
a furnace, which is an autoclave enabling the layer to be cured with temperature and/or pressure and applying temperature and/or pressure to the layer at a temperature and/or pressure value predetermined by a user
Implementation Method 3
a furnace, which is an autoclave enabling the layer to be cured with temperature and/or pressure
Implementation Method 4
an additional vacuum bag which surrounds inner wall surface of the mold not contacting the fabric, allowing it to be vacuumed, wherein according to temperature and/or pressure and/or time parameters predetermined by the user, the vacuum bag enables the mold to withstand the pressure inside the furnace to which it is exposed
Data Source
AI summary
The present invention relates to at least one mold (2) produced by additive manufacturing method; at least one layer (3) (laminated) of resin-impregnated fabrics laid on an outer wall surface of the mold (2); at least one vacuum bag (4) which is placed to substantially cover the layer (3) and allows vacuuming; at least one furnace (5) which enables the layer (3) to be cured by heating, applies pressure to the layer (3) at a pressure value predetermined by the user, and into which the mold (2) is placed; at least one part (6) formed by curing the layers (3).