AM Support Tool Structure for Stable Composite Part Trimming
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Solution Overview
Problem
Existing support tools for manufacturing large composite aircraft parts are heavy, costly, and prone to dimensional instability due to their large size and material limitations, making them difficult to transport and maintain precision during the trimming process.
Innovation Solution
An additively manufactured support tool assembly comprising a rigid support frame and a contoured support tool with a monolithic structure of additive manufactured layers, which provides sufficient strength and rigidity to maintain dimensional stability within allowable tolerances, and is designed to accommodate large surface areas while being lighter and less expensive than traditional metal tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal plate support tools are used to support large working components, then the support tool can provide sufficient structural strength and stability, but the support tool becomes extremely heavy and expensive to manufacture
Solution Approach 1:
The support tool is divided into multiple modular components including a base plate, vertical support members, and adjustable positioning mechanisms. These segmented modules can be assembled in different configurations to support various component sizes, reducing the need for single large heavy metal plates while maintaining structural strength through distributed load bearing.
Solution Approach 2:
The support tool incorporates composite construction using lighter materials such as aluminum alloys, composite beams, and engineered wood in conjunction with steel only where high strength is critically needed. This composite approach reduces overall weight while maintaining sufficient structural strength through strategic material placement and hybrid construction.
2Area of stationary object
If the support tool is made large enough to accommodate the entire working component surface, then the support tool can provide complete coverage, but the support tool becomes difficult to transport and handle
Solution Approach 1:
The large support tool surface is segmented into multiple smaller modular sections that can be easily transported and assembled. These modular units can be configured to cover the required surface area when assembled together, making individual components manageable in size for transport while providing complete coverage when assembled.
Solution Approach 2:
The support tool design transitions from a single large planar surface to a three-dimensional modular structure that can be collapsed or disassembled for transport. The modular components can be stacked or nested, utilizing vertical space during transport rather than requiring large horizontal space, thereby improving transportability while maintaining large surface area capability when deployed.
3Stability of the object's composition
If the support tool uses thick metal plate construction to maintain dimensional stability, then the support tool can resist warping and deformation, but the manufacturing cost and weight increase significantly
Solution Approach 1:
The support tool uses multiple thinner modular components assembled together to achieve the dimensional stability that would otherwise require thick metal plates. The modular joints and connections are designed to maintain rigidity and prevent warping, distributing structural loads across multiple components rather than requiring excessive thickness in a single plate.
Solution Approach 2:
The support tool employs composite construction using materials with high stiffness-to-weight ratios and engineered material properties that provide dimensional stability without requiring thick sections. Strategic use of reinforcing elements, ribs, and bracing in the composite structure maintains rigidity and resists warping at reduced material thickness and cost.
4Reliability
If the support tool is constructed with sufficient thickness to prevent cracking under transport forces, then the support tool can withstand transportation, but the support tool becomes heavier and more expensive
Solution Approach 1:
The support tool is segmented into multiple components connected by flexible yet strong joints that can absorb transport shocks and forces. This segmentation allows the structure to flex and dissipate transport forces without requiring excessive thickness, reducing weight while maintaining durability during transportation.
Solution Approach 2:
The support tool uses composite materials with high impact resistance and toughness that can withstand transportation forces without requiring thick construction. The composite structure absorbs shock and vibration during transport, providing durability at reduced weight compared to solid thick metal construction.
Data Source
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AI summary
A support tool (104) for a tool assembly (100) is supported by a support frame (102) and includes a faceplate (110) and a supporting grid structure (112) formed with the faceplate as a monolithic structure defined by a series of AM layers (114). The faceplate has a supporting surface (116) at a top (120) of the support tool for supporting a working component (106). The supporting grid structure engages the support beams such that loads are transferred between the support tool and the support frame through the support beams. The support frame maintains dimensional stability of the support tool during transport and when resting within an allowable tolerance of the support tool.