Masterless Layup Mandrel for Composite Fabrication
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current composite part fabrication methods require complex and costly master tools, which can be time-consuming and logistically challenging, especially for large-scale production like aircraft components, where rapid fabrication and reduced logistics costs are desirable.
Innovation Solution
A method for creating a masterless layup mandrel tool using a cellular structure filled with a foam-like material, which is machined to form a composite face sheet, allowing for the fabrication of composite parts without a permanent mold, and utilizing a fabrication cell with clean and dirty sections to manage operations effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional master tools are used for composite part fabrication, then manufacturing precision is maintained, but device complexity and logistics costs increase
Solution Approach 1:
The patent creates a digital copy (3D digital model) of the master tool surface and uses it to generate toolpath instructions for automated material placement. This digital copying eliminates the need for physical master tools while maintaining the precision required for high-quality composite part fabrication. The digital model serves as the master reference, and automated systems replicate the surface geometry through layer-by-layer material deposition.
Solution Approach 2:
The patent replaces the mechanical master tool system with an automated material placement system guided by digital models and computer-controlled mechanisms. Instead of using physical master tools that require shipping and handling, the system uses digital instructions to control automated layup processes, eliminating the mechanical master tool while maintaining manufacturing precision through automated control.
2Manufacturing precision
If master tools are fabricated and shipped to fabrication sites, then manufacturing precision is ensured, but loss of time and logistics costs increase
Solution Approach 1:
The patent performs preliminary actions by creating the digital master tool model and generating the toolpath instructions in advance at a centralized location. These digital instructions are then transmitted electronically to remote fabrication sites, eliminating the need to physically ship master tools. The preliminary digital preparation enables rapid deployment to multiple sites without the time loss associated with tool fabrication and transportation.
Solution Approach 2:
The patent uses digital copying to replicate the master tool surface geometry and transfer it electronically to remote fabrication sites. Instead of physically transporting the master tool, the digital model is copied and transmitted, enabling immediate fabrication at remote locations while maintaining dimensional accuracy through precise digital-to-physical replication via automated material placement.
3Manufacturing precision
If clean room environment is maintained for all operations, then manufacturing precision is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent applies different environmental quality requirements to different operational zones. The automated material placement system operates in a controlled clean room environment where precision is critical, while subsequent operations such as machining, trimming, and finishing are performed in less restrictive environments. This local differentiation of cleanliness requirements maintains manufacturing precision where needed while simplifying operations elsewhere.
Solution Approach 2:
The patent segments the fabrication process into distinct phases with different environmental requirements. The critical layup phase is isolated in a clean room environment, while post-processing operations are separated into different zones with relaxed environmental controls. This segmentation allows the clean room to be used only when necessary for precision work, reducing overall operational complexity and cost.
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 reduces production time and costs by enabling rapid fabrication of composite parts with improved surface finish and durability, while minimizing logistics and shipping expenses, and allows for on-site fabrication of mandrel tools, reducing the need for oversized loads and enabling remote location of fabrication cells.
Implementation Method 1
machining the foam-like material to obtain a machined surface
Implementation Method 2
laying up composite material on the machined surface to form the face sheet
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method of fabricating a composite part including reinforcing fibers comprises fabricating a masterless layup mandrel tool at a fabrication site. The tool includes a composite face sheet that provides a layup surface. The method further comprises using the masterless tool at that site to form a layup of the reinforcing fibers.