Pre-Cure Feature Forming for Precise Composite Components

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Forming accurate and precise features such as embossments, countersinks, and counterbores in composite components like ceramic matrix composite (CMC) and polymer matrix composite (PMC) materials is challenging, often requiring additional material and labor due to traditional machining methods that weaken the composite material.

Innovation Solution

A method and assembly that form features in composite components by using a base tool with recesses and a feature forming tool with inserts, allowing the features to be integrated during the fabrication process without post-machining, utilizing a combination of materials like silicone and harder materials for the sheet and inserts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional machining methods are used to form features in composite components, then features such as embossments, countersinks, and counterbores can be created, but the composite material is weakened and additional material and labor are required

Engineering Contradiction:

Improvefeature accuracyVSAvoidcomposite material strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The feature forming tool with inserts is applied to the composite material during the fabrication process before final curing, allowing features to be formed while the material is still pliable. This preliminary action eliminates the need for post-curing machining operations that would weaken the cured composite material.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of machining features into the cured composite material (traditional approach), the invention inverts the process by forming features during fabrication while the material is in a formable state. This reverses the sequence of operations to avoid weakening the final cured material.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If traditional machining methods are used to form features in composite components, then features can be created, but additional composite material is required to provide adequate machining area

Engineering Contradiction:

Improvefeature accuracyVSAvoidcomposite material quantity

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

Features are formed during the fabrication process before curing, eliminating the need for additional material allowances required for post-curing machining operations. The exact feature geometry can be achieved directly without requiring extra material for machining removal.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If traditional machining methods are used to form features in composite components, then features can be created, but labor costs increase due to post-processing requirements

Engineering Contradiction:

Improvefeature accuracyVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The feature forming operation is merged with the fabrication process by using a feature forming tool with inserts that can be applied during material layup and curing. This combines what were previously separate operations (fabrication and feature creation) into a single integrated process, eliminating post-processing machining steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Features are formed during the fabrication process itself rather than as a separate post-processing step. This preliminary formation of features during manufacturing reduces the number of discrete operations required and lowers overall labor costs.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If traditional machining methods are used to form features in composite components, then features can be created, but the component requires additional material beyond the actual component geometry

Engineering Contradiction:

Improvefeature accuracyVSAvoidmaterial waste

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

Features are formed during fabrication before curing, allowing precise feature geometry to be created without requiring additional material allowances for post-curing machining. This eliminates material waste associated with machining removal operations on cured components.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3385063B1Methods for forming features in composite components

Publication Date: 2025.10.15 GENERAL ELECTRIC CO

Figure 1
Figure 2
Figure 3~3B

AI summary

Various methods and assemblies are provided for producing composite components (90) having formed in features. For example, a method may comprise depositing a composite material (102) on a base tool (100,200,300,400); deploying a feature forming tool (110,210,30,410,510) to press the composite material (102) into one or more recesses (104,204,304); and processing the composite material (102) with the feature forming tool (110,210,30,410,510) pressing the composite material (102) into the one or more recesses (104,204,304). The processed composite material (102) forms a green state composite component. The feature forming tool (110,210,30,410,510) comprises one or more forming members (214), supported by a frame (212), for forming one or more features of the composite component (90). The method also may include sealing a bag (125) around the composite material (102) before deploying a feature forming tool (110,210,30,410,510) and removing the feature forming tool (110,210,30,410,510) and the bag (125) after processing the composite material (102).