Composite Fuselage Section Tooling Transfer Method
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Solution Overview
Problem
The manufacturing of composite fuselage sections for aircraft is rate-limited by the availability of inner mold line tools, as each tool can only be used for one section at a time, leading to increased costs and limited production capacity due to the need for multiple tools and space constraints.
Innovation Solution
A method involving a temporary removal layer and an expandable tool allows for the transfer of composite parts from an inner mold line tool to an outer mold line tool, enabling the inner mold line tool to be freed up for another section while the current section is processed, and utilizing a vacuum bag system for curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple inner mold line tools are used to increase production capacity, then productivity increases, but device complexity and manufacturing costs increase
Solution Approach 1:
The mold line tool is divided into two separate components: an inner mold line tool and an outer mold line tool. The inner tool is used for laying up composite material, while the outer tool is used for curing. This segmentation allows the inner tool to be freed and reused for another section while the current section cures in the outer tool, effectively doubling the utilization rate of tooling equipment and increasing production capacity without requiring proportional increases in total tooling inventory.
Solution Approach 2:
The inner mold line tool is positioned inside the outer mold line tool during the curing process. The composite material is laid up on the inner tool, which is then nested within the outer tool that contains the curing cavity. This nesting arrangement allows simultaneous use of both tools for different purposes - the inner tool can be removed and used for another section while the outer tool continues to cure the current section, thereby increasing productivity without requiring additional tools.
2Manufacturing precision
If the inner mold line tool is used throughout the entire manufacturing process, then manufacturing precision is maintained, but productivity decreases due to tool unavailability
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: laying up (forming) and curing. The inner mold line tool is dedicated to the laying up phase, while the outer mold line tool is dedicated to the curing phase. This segmentation allows the inner tool to be freed immediately after laying up is complete, enabling it to be used for another section while the current section cures in the outer tool. This resolves the contradiction by allowing the tool to be reused without compromising the quality of the current part, as the curing process in the outer tool ensures manufacturing precision is maintained.
Solution Approach 2:
The outer mold line tool acts as an intermediary curing chamber that receives the inner mold line tool after laying up. The inner tool with the formed composite part is transferred into the outer tool, which then provides the controlled environment for curing. This intermediary arrangement allows the inner tool to be liberated for reuse while the outer tool ensures the curing process maintains manufacturing precision and quality standards.
3Productivity
If multiple inner mold line tools are acquired to increase production rates, then productivity increases, but manufacturing costs increase
Solution Approach 1:
By dividing the tooling system into inner and outer components with distinct functions, the same inner tool can be reused multiple times for different sections while the outer tool handles curing. This eliminates the need to purchase multiple complete tooling systems, significantly reducing capital equipment costs while still achieving high production rates through increased tool utilization.
Solution Approach 2:
The outer mold line tool serves multiple purposes: it acts as the curing chamber for one section while simultaneously serving as the housing that allows the inner tool to be removed and reused for another section. This multi-functionality maximizes the utility of each tooling investment, reducing the total number of tools needed and thereby lowering manufacturing costs while maintaining high productivity.
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 increases production efficiency by allowing multiple composite parts to be processed simultaneously, reducing the time needed for each part and enabling parallel operations, thereby enhancing production rates and reducing costs.
Implementation Method 1
A vacuum bag system may be installed over the composite part on the outer mold line tool after removing the expandable tool and the temporary removal layer
Data Source
AI summary
A method for manufacturing composite parts. A temporary removal layer may be placed on an inner mold line tool. A composite material may be laid up on the inner mold line tool for a composite part. The inner mold line tool may be positioned with the composite part inside an outer mold line tool. The composite part and the temporary removal layer may be transferred from the inner mold line tool to the outer mold line tool. The inner mold line tool and the temporary removal layer may be removed from inside of the outer mold line tool after transferring the composite part and the temporary removal layer to the outer mold line tool.