Masterless Layup Mandrel Tool Using Cellular Header Boards
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Solution Overview
Problem
The existing methods for fabricating composite parts using layup mandrel tools are often slow and require permanent molds, limiting rapid prototyping and repair capabilities, especially for complex parts like aircraft components.
Innovation Solution
A masterless layup mandrel tool is created using a cellular structure of header boards filled with a foam-like material, which is machined to provide a stable surface for composite material layup and curing, allowing for customizable tool durability and reduced production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If permanent molds are used for fabricating composite parts, then manufacturing precision is improved, but productivity is reduced and device complexity increases
Solution Approach 1:
The patent employs disposable header boards made from inexpensive materials like MDF, plywood, or foam core instead of permanent molds. These boards are used for a limited number of layup cycles (typically 5-50 times) and then discarded, eliminating the time-consuming process of manufacturing, maintaining, and repairing permanent molds while achieving sufficient dimensional stability for the application.
Solution Approach 2:
The patent uses composite construction for the header boards, combining different materials (wood, foam, metal reinforcement) to achieve the required structural properties. This allows the tool to provide adequate dimensional stability and surface finish without the complexity and cost of permanent metal molds, enabling faster tool fabrication and replacement.
2Reliability
If permanent molds are used for fabricating composite parts, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces complex, expensive permanent molds with simple, disposable header boards. The boards are designed for limited-use applications where high durability is not required, significantly reducing tool structure complexity and manufacturing cost while maintaining adequate reliability for the intended number of use cycles.
Solution Approach 2:
The tool is divided into modular header boards that can be individually replaced without affecting the entire tool structure. This segmentation allows for simpler individual components with lower complexity, while the modular assembly maintains overall tool reliability through easy replacement of worn sections.
3Manufacturing precision
If traditional layup tools are used, then manufacturing precision is maintained, but loss of time increases due to tool fabrication and maintenance
Solution Approach 1:
The patent uses inexpensive, easily fabricated header boards that can be quickly manufactured or acquired and then used immediately for layup. This eliminates the lengthy tool preparation and maintenance cycles associated with permanent molds, reducing time loss while achieving acceptable surface finish through the boards' inherent smooth surfaces.
Solution Approach 2:
The header boards are pre-prepared with the required surface characteristics and dimensional accuracy before use. This preliminary preparation is done quickly using simple materials and methods, eliminating the need for time-consuming tool conditioning, heating, or complex setup procedures required by traditional permanent molds.
Data Source
AI summary
A mandrel tool for layup of composite material comprises a composite face sheet for providing a layup surface for the composite material, and a cellular header board structure for supporting the face sheet.