Hybrid Layup Tool with Metallic Support and 3D Printed Backing
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Solution Overview
Problem
Traditional layup tools, whether metallic or composite, are costly and time-consuming to fabricate, making them prohibitive for prototype or developmental programs, and tools made from low-cost materials lack the strength and reliability needed for robotic composite manufacturing.
Innovation Solution
A layup tool comprising a metallic support structure and a non-metallic backing structure with a complementary contour, where the non-metallic backing structure is additively manufactured using 3D printing and the support structure is made from metallic materials like aluminum, with floating connections to accommodate thermal expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metallic or composite layup tools are used, then strength and reliability are ensured, but fabrication time and cost become prohibitive for prototype or developmental programs
Solution Approach 1:
The layup tool is divided into two distinct segments: a metallic support structure providing strength and rigidity, and a separate non-metallic backing structure providing the working surface. This segmentation allows each component to be optimized independently for its specific function while reducing overall fabrication time compared to traditional monolithic tools.
Solution Approach 2:
The invention employs a composite construction combining metallic materials (for the support structure) with non-metallic materials (for the backing structure). This composite approach leverages the advantages of both material types: the strength and reliability of metals and the ease of fabrication and complex shape capability of non-metallic materials, thereby reducing fabrication time while maintaining tool performance.
2Shape
If traditional composite layup tools are used, then complex working surfaces can be achieved, but additional molding steps increase fabrication cost and time
Solution Approach 1:
The complex working surface functionality is extracted from the structural support function. The backing structure, which provides the complex working surface, is separated from the metallic support structure. This allows the backing structure to be fabricated using additive manufacturing or other efficient processes specifically optimized for complex geometries, eliminating the need for additional molding steps required by traditional composite tools.
Solution Approach 2:
The complex working surface of the tool is designed as a complementary contour that copies or mirrors the target workpiece geometry. This copying approach, combined with additive manufacturing of the backing structure, enables rapid production of complex shapes without requiring traditional multi-step molding processes, thereby reducing fabrication cost and time.
3Ease of manufacture
If low-cost materials like plaster or foam are used for layup tools, then fabrication cost is reduced, but strength and reliability are insufficient for robotic composite manufacturing
Solution Approach 1:
The tool is segmented into a metallic support structure that provides the necessary strength and reliability for robotic manufacturing, and a non-metallic backing structure that can be made from cost-effective materials. This segmentation allows low-cost materials to be used for the backing structure while the metallic support structure ensures overall tool strength and reliability.
Solution Approach 2:
The hybrid composite construction combines metallic materials (providing strength and reliability) with non-metallic materials (providing cost-effectiveness). This composite approach enables the use of lower-cost materials for portions of the tool where full structural strength is not required, while maintaining overall tool reliability through the metallic support structure.
4Adaptability or versatility
If different materials with different thermal expansion coefficients are combined, then fabrication flexibility is improved, but thermal expansion mismatches cause distortion
Solution Approach 1:
The invention addresses thermal expansion mismatches by carefully selecting and controlling material parameters, specifically the thermal expansion coefficients of the metallic and non-metallic materials. By matching or coordinating these parameters, the design achieves fabrication flexibility with different materials while minimizing thermal distortion and maintaining dimensional stability during curing operations.
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
The solution enables the rapid, cost-effective production of complex shapes for layup tools, reducing fabrication time and costs while maintaining the necessary strength and reliability for robotic composite manufacturing, and mitigates issues related to thermal expansion.
Implementation Method 1
floating connections to accommodate thermal expansion differences
Data Source
AI summary
A tool for laying up composite material to form a workpiece having a target contour is disclosed. The tool includes a support structure including an elongated member having a longitudinal axis, and support plates connected to the elongated member and spaced apart from each other along the longitudinal axis. The elongated member includes a metallic material. The tool also includes a non-metallic backing structure connected to the support plates, the non-metallic backing structure comprising a working surface that includes a backing contour complementary to the target contour.