Tool-less Resin Infusion via Additive Part Skeletons

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Solution Overview

Problem

The manufacturing of composite parts using resin infusion processes is hindered by the need for expensive and complex tooling, which can be damaged during storage or transport, and the difficulty in achieving precise tolerances for complex structures like compound contours and undercuts.

Innovation Solution

A tool-less resin infusion system that uses additive manufacturing to print a part skeleton, which is then infused with resin and cured, eliminating the need for hard tooling and allowing for the production of complex composite parts without the requirement for intricate tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If expensive precision metallic tooling is used for laminate production, then manufacturing precision and reliability are improved, but device complexity and cost increase significantly

Engineering Contradiction:

Improvedimensional toleranceVSAvoidtooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a digital 3D model as a virtual copy of the final part to generate tooling paths and instructions for robotic arms. This digital copying eliminates the need for physical precision tooling while maintaining manufacturing accuracy through software-controlled replication of the desired geometry.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces traditional mechanical precision tooling with a robotic system controlled by software. The robotic arm with customizable end effectors uses programmable motion control instead of fixed mechanical tooling, allowing precise fabrication without expensive metallic molds or fixtures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If precision metallic tooling is used for composite part fabrication, then manufacturing precision is improved, but loss of time occurs due to tool damage, repair, and replacement

Engineering Contradiction:

Improvedimensional toleranceVSAvoidproduction delay

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent employs disposable or easily replaceable consumable materials such as foam blocks, wax, or sacrificial support structures that are removed after forming the composite part. These inexpensive temporary forms eliminate the risk of production delays associated with damaging expensive precision tooling, as they can be quickly replaced without repair.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces durable but vulnerable metallic tooling with a software-controlled robotic system that uses programmable paths and customizable end effectors. This eliminates mechanical wear and damage issues, allowing continuous production without downtime for tool maintenance or replacement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If traditional laminate fabrication processes are used, then manufacturing simplicity is maintained, but adaptability to complex geometries deteriorates

Engineering Contradiction:

Improveprocess simplicityVSAvoidgeometry complexity

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent uses a dynamic robotic system with programmable motion control and customizable end effectors that can adapt to various complex geometries. The system combines the simplicity of automated deposition processes with the versatility to handle compound contours, undercuts, and three-dimensional shapes through software-controlled toolpath generation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the state of the manufacturing system from fixed mechanical tooling to a programmable robotic system with variable parameters. The end effectors can be configured with different properties (heating, dispensing, curing) and the robotic paths can be adjusted to match any geometry, maintaining process simplicity while achieving geometric versatility.

Inventive Principle:

Principle #35Parameter changes

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

Enables the production of composite parts with complex geometries and structures without the need for expensive tooling, reducing production delays and costs while maintaining precise tolerances.

Implementation Method 1

covering the part skeleton with a permeable release film

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

infusing the covered part skeleton with resin

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentUS11548242B2Multi-planar fiber matrix tool-less preform for resin infusion

Publication Date: 2023.01.10 THE BOEING CO

AI summary

A system and method for manufacturing composite parts has been developed which offers the ability to produce composite parts in an infusion resin process without the use of expensive preforms or tools. In addition, the methods of manufacturing composite parts described herein offer the ability to produce composite parts having complex structures without the need for complex tooling. The method of manufacturing and systems described herein typically include printing a part skeleton using an additive manufacturing process followed by infusing the part skeleton with resin and curing the resin infused part skeleton to form the composite part.