Additive Polymer Mold Shell with Reinforcement for Composite Parts
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Solution Overview
Problem
The existing methods for composite molding often require additional processing steps to achieve the desired features and surface finish for composite parts, as metal or foam molds may not easily incorporate complex features, leading to increased processing time and costs.
Innovation Solution
The method involves additively manufacturing a polymer-based mold shell with reinforcement structures and a conformal system, filled with a strengthening agent like epoxy or resin, which is then cured to form a mold for laying up composite materials, reducing the need for post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal or foam molds are used for composite molding, then the mold can withstand the required temperature and pressure, but additional processing steps are required to achieve desired features and surface finish
Solution Approach 1:
The patent uses a composite mold structure combining a polymer-based mold shell with embedded reinforcement structures (such as metal inserts, foam cores, or structural additives) to achieve both the required mechanical strength for withstanding curing temperatures and pressures, and the ability to produce complex features and smooth surface finishes without extensive post-processing. The reinforcement structures are integrated during the additive manufacturing process, eliminating the need for separate strengthening steps.
Solution Approach 2:
The patent employs additive manufacturing parameters and material selection to create a mold shell with optimized properties that can withstand curing conditions while providing the desired surface quality. By controlling layer thickness, infill patterns, and material composition during additive manufacturing, the mold achieves both structural integrity and surface finish requirements, eliminating the need for additional processing steps.
2Reliability
If metal or foam molds are used, then the mold can withstand curing conditions, but complex features are difficult to manufacture
Solution Approach 1:
The composite mold structure allows for the integration of complex geometric features directly into the mold shell through additive manufacturing, while the embedded reinforcement structures provide the necessary strength to withstand curing conditions. The combination enables intricate details and smooth surfaces to be manufactured as-is, without requiring post-processing operations.
Solution Approach 2:
The additive manufacturing process parameters are optimized to produce the desired complex features with high precision, while the reinforcement structure parameters are adjusted to ensure the mold can withstand the curing conditions. This dual optimization allows complex geometries to be manufactured directly with the required structural integrity.
3Manufacturing precision
If additional processing steps are performed on metal or foam molds, then the desired surface finish is achieved, but production time and costs increase
Solution Approach 1:
The additive manufacturing parameters are optimized to directly produce the desired surface finish on the mold shell, eliminating the need for post-processing operations such as sanding or polishing. The reinforcement structures are integrated during manufacturing rather than added as separate components, significantly reducing production time and improving manufacturing efficiency while maintaining high surface quality.
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 allows for the creation of composite parts with minimal additional processing, achieving complex features and a smooth surface finish while reducing production time and costs, similar to metal or metal alloy molds but with improved surface quality and reduced post-processing needs.
Implementation Method 1
hardening the strengthening agent to form a mold
Data Source
AI summary
A method and system for composite molding, and the method includes additively manufacturing a mold shell that includes a part forming cavity. The method includes filling at least a portion of the mold shell with a strengthening agent. The method includes hardening the strengthening agent to form a mold, and laying-up a composite material on the part forming cavity. The method includes curing the mold to form a composite part.