3D Printed Invar Tooling Shells for Complex Panel Molding
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Solution Overview
Problem
Conventional machining techniques for producing tooling shells are labor-intensive, costly, and result in bulky, unwieldy tools with limited geometrical complexity, making it difficult to manufacture panels with complex shapes and increasing production costs and time.
Innovation Solution
The use of 3-D printed tooling shells, specifically made from materials like Invar or similar alloys, which provide thermal stability and stiffness, allows for the creation of complex geometries and reduced tool mass, enabling more efficient and cost-effective production of composite panels with integrated channels for resin infusion, vacuum generation, and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining techniques are used to produce tooling shells, then the tooling shells can be manufactured with traditional materials, but the process becomes labor-intensive, costly, and results in bulky, unwieldy tools with limited geometrical complexity
Solution Approach 1:
The patent changes the manufacturing method from conventional machining to 3-D printing, fundamentally altering how tooling shells are produced. This enables complex geometries that would be difficult or impossible to machine traditionally, while reducing material waste and manufacturing time. The 3-D printing process allows for integrated channels and hollow sections that cannot be easily created through machining.
Solution Approach 2:
The patent applies different material properties and structural characteristics to different regions of the tooling shell. The 3-D printed structure allows for varying wall thicknesses, density, and material composition in different areas, optimizing both structural integrity and weight reduction. Hollow sections and integrated channels are strategically placed to achieve specific functional requirements.
2Stability of the object's composition
If conventional machining techniques are used to produce tooling shells, then traditional manufacturing methods can be maintained, but production costs and time increase
Solution Approach 1:
The patent incorporates channels, hollow sections, and other features directly into the 3-D printed tooling shell during the manufacturing process itself, rather than adding them through subsequent machining or assembly operations. This preliminary integration of features significantly reduces production time and the number of manufacturing steps required.
Solution Approach 2:
The patent combines multiple manufacturing operations into a single 3-D printing process. Features that would traditionally require separate machining, welding, or assembly steps are all created in one additive manufacturing process, reducing both time and labor costs while maintaining material consistency.
3Weight of moving object
If 3-D printed tooling shells are used, then complex geometries and reduced tool mass are achieved, but new manufacturing technology must be implemented
Solution Approach 1:
The patent utilizes hollow sections and porous-like structures within the 3-D printed tooling shell to reduce weight while maintaining structural integrity. These internal voids and lattice structures allow for significant weight reduction compared to solid machined tools, while the 3-D printing process makes it easy to create these complex internal geometries.
4Adaptability or versatility
If 3-D printed tooling shells with integrated channels are used, then resin infusion, vacuum generation, and heat transfer are enabled, but the manufacturing process becomes more complex
Solution Approach 1:
The patent designs the 3-D printed tooling shell to perform multiple functions simultaneously. The same structure provides structural support, contains integrated channels for resin infusion and vacuum generation, and facilitates heat transfer. This multi-functionality is achieved through the flexibility of 3-D printing, which allows complex geometries to be created without proportionally increasing manufacturing complexity.
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
3-D printed tooling shells facilitate the production of lightweight, complex panel designs with reduced material usage and thermal cycle time, enhancing manufacturing flexibility and reducing costs, while maintaining structural integrity and thermal stability.
Implementation Method 1
3-D printed tooling shells, specifically made from materials like Invar or similar alloys, which provide thermal stability and stiffness
Implementation Method 2
3-D printed tooling shell including a channel to enable resin infusion, vacuum generation, or heat transfer
Data Source
AI summary
Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell.