Additive Manufacturing Tool with Epoxy Resin Cavity

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Solution Overview

Problem

The aerospace industry faces challenges in creating tools for spare parts and modifications, as existing methods like numerical control machining are time-consuming and expensive, especially when dealing with low-volume production and frequent design changes, leading to increased lead times and costs.

Innovation Solution

An additive manufacturing method involving a shell with a support structure, filled with a thermally conductive epoxy resin, which is cured to form a tool that can withstand pressure and temperature for manufacturing composite aircraft parts, reducing the need for costly materials and time-consuming numerical control programming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If numerical control machining is used to create tools, then manufacturing precision is achieved, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improvetool manufacturing precisionVSAvoidtool creation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The tool is divided into two functional parts: a precision-machined shell (created via additive manufacturing) and a filler material (epoxy resin) that is poured into the shell. This segmentation allows the precision requirements to be met by the shell while the filler provides the functional working surface, eliminating the need for time-consuming full-tool machining operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a digital model (CAD file) to directly guide additive manufacturing of the shell, creating a precise copy of the desired tool geometry without requiring traditional machining operations. This digital copying approach significantly reduces manufacturing time while maintaining precision.

Inventive Principle:

Principle #26Copying

2Strength

If traditional tool manufacturing methods are used, then tool strength and durability are ensured, but material cost and processing time increase

Engineering Contradiction:

Improvetool strengthVSAvoidtool manufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The tool is created as a composite structure combining the shell (made from durable materials like aluminum or steel via additive manufacturing) and the filler material (epoxy resin). This composite approach ensures the tool has sufficient strength and durability while reducing the amount of expensive metal material needed and eliminating time-consuming machining operations.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the manufacturing parameters from traditional subtractive machining to additive manufacturing followed by curing. This parameter change allows the tool to be built layer-by-layer with precise control over material deposition, ensuring strength while dramatically reducing manufacturing time.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If tools are remanufactured for spare parts and modifications, then part availability is improved, but cost and time expenses increase

Engineering Contradiction:

Improvepart availabilityVSAvoidtool remanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The shell is pre-manufactured using additive manufacturing technology, which can store digital models for future tool creation. When spare parts or modifications are needed, the pre-prepared digital model can be quickly reused to create new tools, ensuring part availability while minimizing remanufacturing costs and time.

Inventive Principle:

Principle #10Preliminary action

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 approach significantly reduces the time and cost of tool creation, allows for rapid production of tools, and minimizes material usage, enabling quicker reaction to design changes and reducing the overall expense of aircraft manufacturing and maintenance.

Implementation Method 1

The shell may be cured with the filler material to form the tool

Methodology Applied

Scientific EffectCuring: Phase Change

Implementation Method 2

A thermosetting epoxide polymer may be formed in a liquid state. A catalyst may be mixed with the thermosetting epoxide polymer in the liquid state to form an epoxy resin

Methodology Applied

Scientific EffectThermosetting polymerization: Chemical Bonding

Implementation Method 3

A shell may be formed having a support structure located in a cavity in which the shell and the support structure may be formed using an additive manufacturing system from a design of a tool

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 4

The cavity of the shell may be filled with a filler material through an opening in the shell

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS8178033B2Method and apparatus for rapidly generating aerospace tools

Publication Date: 2012.05.15 THE BOEING CO

AI summary

A method and apparatus may be present for manufacturing. A shell may be formed having a support structure located in a cavity in which the shell and the support structure may be formed using an additive manufacturing system from a design of a tool. The cavity of the shell may be filled with a filler material through an opening in the shell. The shell may be cured with the filler material to form the tool.