Segmented Mandrel with Crush Inserts for Composite Forming
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Solution Overview
Problem
Existing mandrels for forming composite structures are often heavy, expensive, and require lengthy design and production times, with materials like steel being costly and time-consuming to produce, and materials like plaster being fragile and difficult to remove without damage.
Innovation Solution
A mandrel formed from multiple segments created through additive manufacturing, with crush inserts positioned between segments to allow for thermal expansion without deforming the mandrel, enabling faster and more cost-effective production of composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials like steel or plaster are used to form mandrels, then the mandrel provides structural support during composite formation, but the production time and cost increase significantly
Solution Approach 1:
The mandrel is divided into multiple separable segments that can be independently manufactured through additive manufacturing and then assembled. This segmentation enables faster production compared to traditional monolithic mandrels while maintaining structural integrity during composite formation.
Solution Approach 2:
The invention changes the material parameters by using additive manufacturing materials with appropriate thermal expansion properties. The crush inserts are designed with specific compression characteristics to accommodate thermal growth during curing, enabling the use of faster additive manufacturing processes while maintaining mandrel reliability.
2Strength
If traditional mandrel designs are used, then structural integrity is maintained, but design changes and innovation become time-consuming
Solution Approach 1:
The segmented mandrel design allows individual segments to be independently modified and replaced. This enables rapid design iterations and innovations without requiring complete mandrel redesign, significantly improving productivity while maintaining overall structural integrity through the assembled segments.
Solution Approach 2:
The mandrel segments can be easily disassembled and replaced when design changes are needed. Instead of discarding the entire mandrel, only specific segments need to be updated, allowing rapid design changes and innovation while recovering and reusing other segments.
3Ease of manufacture
If mandrels are made from single-piece construction, then manufacturing is simpler, but thermal expansion during curing causes deformation
Solution Approach 1:
The segmented construction allows each segment to independently accommodate thermal expansion without causing overall mandrel deformation. The gaps and crush inserts between segments provide controlled compliance, maintaining manufacturing precision while keeping the manufacturing process relatively simple through additive manufacturing.
Solution Approach 2:
The invention explicitly accounts for thermal expansion by designing crush inserts that compress during curing to accommodate the thermal growth of the composite material. This prevents deformation of the mandrel while allowing controlled thermal expansion, maintaining dimensional stability without complex single-piece construction.
4Manufacturing precision
If crush inserts are positioned between segments, then thermal expansion is accommodated without deformation, but mandrel structure becomes more complex
Solution Approach 1:
The crush inserts are specifically designed to compress under thermal expansion forces during curing, accommodating dimensional changes without deforming the overall mandrel structure. This relatively simple mechanism effectively manages thermal expansion without requiring complex structural modifications.
Solution Approach 2:
The crush inserts act as compliant elements between rigid segments, providing controlled flexibility to accommodate thermal expansion. This simple flexible element approach effectively manages thermal effects without significantly increasing overall mandrel structural complexity.
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
The use of additive manufacturing and crush inserts allows for the creation of a reusable mandrel that reduces production costs and time, enabling faster design changes and innovation in composite structures while minimizing damage during mandrel removal.
Implementation Method 1
positioning a crush insert between adjacent segments
Data Source
AI summary
A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.