Tooling 101 for Composites Manufacturing

1 1 Tooling 101 for Composites ManufacturingDr. Scott W. Beckwith, FSAMPESAMPE Global Technical DirectorPresident, BTG Composites , 19, 2020 The Market AreasAerospace Commercial Aircraft Business Aircraft General Aviation Aircraft Military Fixed-Wing Rotorcraft (Helicopters) Jet Engines Space & Launch Vehicles Missiles & Munitions Carbon-Carbon OthersIndustrial Automotive Energy Systems General Engineering Infrastructure Friction materials Rollers Medical Compounds Tooling (across all areas) OthersConsumer Sports & Recreation Golf Tennis Fishing Racquets Bicycles Winter Sports Spring Sports Archery Hockey Others Marine Amusement Structures Others3 The Market AreasAerospace Commercial Aircraft Business Aircraft General Aviation Aircraft Military Fixed-Wing Rotorcraft (Helicopters) Jet Engines Space & Launch Vehicles Missiles & Munitions Carbon-Carbon Tooling (across all areas) OthersIndustrial Automotive Energy Systems General Engineering Infrastructure Friction materials Rollers Medical Compounds Tooling (across all areas)

2 OthersConsumer Sports & Recreation Golf Tennis Fishing Racquets Bicycles Winter Sports Spring Sports Archery Hockey Others Marine Amusement Structures Tooling (across all areas) Others4 APPROACH Provide you with an overview of Tooling : Highlight critical tool material properties Various traditional materials Tooling support structures New and innovative materials Tooling for molding processes Tooling design & process considerations Numerous examples .. and many applications5 Tooling MATERIALS & THEIR PROPERTIES6 Frequently Used Tooling Materials Metals: Aluminum Stainless Steel & P20 Steel nickel (Electro-Formed nickel ) Invar 36 & Invar 42 Composites : Glass Fiber Reinforced Plastic (GFRP) Carbon Fiber Reinforced Plastic (CFRP) Other Material Options Numerous 7 PROPERTIES OF TYPICAL Tooling MATERIALSS teelAluminumElectroformed NickelInvar/NiloCarbon/Epoxy 350 FCarbon/Epoxy RT/350 FGlass/Epoxy 350 FGlass/Epoxy RT/350 FMonolithic GraphiteMass Cast CeramicSiliconeIsobutyl 90 ( F)CTEX10-6/ x ft.

3 X FSteelAluminumElectroformed NickelInvar/NiloCarbon/Epoxy 350 FCarbon/Epoxy RT/350 FGlass/Epoxy 350 FGlass/Epoxy RT/350 FMonolithic GraphiteMass Cast CeramicSiliconeIsobutyl 90 ( F)CTEX10-6/ x ft. x F89 METAL Tooling TECHNOLOGY EXAMPLES 10 Manufacturing of Large NC-Machined Steel Bond ToolSteel Plates and Eggcrate SubstructureNC Machining Faceplate ContourCompleted ToolWelding Faceplate Sections1112 STEEL Tooling Steel Mould for End Domes to Underground Storage Tank (UST)13 Fiber and Resin Wet Out inside Steel Tool for Dome Structure14 End Dome Section Priorto Trimming15 End Dome Installed (but Not Bonded) into UST Main Cylinder Body16 Collapsible Steel Mandrel (Full Geometry)17 Steel Mandrel Now Collapsed.

4 18 End View of UST Being Removed from Mandrel19 Filament Wound UST Extracted from Steel Mandrel20 Steel, Tapered Mandrelfor Rocket Motor Case for Space Launch 21 Steel Tooling for Boeing 767 Door Spring22 Boeing 767 Main Door Composites Torsional Spring23 Steel Tool face cut from single billetPhoto courtesy of Process Fab, Molds and Mandrels for Aerospace24 Fiber Placement Mandrel25 AFP Composites Simplify and Speed Manufacturing (Boeing 787 Barrel Section)26 One Piece Barrel Section(Boeing 787)27V-22 Aft Section Fiber Placement28 AFP of Aircraft Stabilizer Section29F-22 Inlet Duct (Complex Internal Tooling )30TP Fiber Placed Tooling by Robotic System3132 ALUMINUM Tooling EXAMPLESA luminum Molds and Fixtures33 Aluminum Molds & Bond FixturesComplex shapes warrant careful CTE Calculations34 Aluminum Fiber Placement Mandrel35 Robotic Fiber Placement Over Metal Mandrel3637 INVAR Tooling EXAMPLESI nvar Layup Mold38 Basic Invar Tool ConstructionPlate stock Plasma cut headersBump-form facesheetAssemble/weldMachine surfaceHand finishFinished tool39 Invar Layup Mold40 Invar Fiber Placement MandrelPhoto courtesy of Fives ManufacturingA-350 Empennage Section 19 Mandrel41 Invar Tooling Cost BreakdownTool eld14%Hand Finish1%Tool Making9%Forming5%Cutting2%Heat Treat1%Material30%HIGHEST FACTORS.

5 Material cost (Invar 36, 42) 30% Machining & Forming cost 38%4243 nickel Tooling EXAMPLESN ickel plating Fabrication Process StepsSource: Metalon, Vapor Deposition (NVD) ProcessSource: CVD Mfg., ( plating ) ProcessMetalon, Inc , Inc. Manufacturing , Inc. nickel Preform MoldNickel Tooling provides durable surface for preforms for class A finish automotive parts45 Electro-Formed nickel Mold46 Electro-Formed nickel Canoe MoldNote: High-polished surface quality of nickel mold47EF nickel Mold for Corvette RoofNickel can be highly polished providing for class A surface finish Photo s courtesy courtesy of Weber Mfgand PlasanCarbon CompositesAdvantages:Durable for high rate production Heated Tooling design provides for OoA capabilities 4849 TITANIUM Tooling EXAMPLEST itanium Shell Liner (Drill Riser Interior)5051 Titanium Shell Liner (Extremely Long)52 PLASTIC Tooling EXAMPLESHDPE Plastic Tank Liners for LPG Tanks53 HDPE = High Density PolyEthylene plastic linerLPG = Liquified Propane GasFive (5)

6 LPG Tanks Wound on Plastic Liner Tools54 End Product LPG Tanks for Homes5556 COMPOSITE Tooling EXAMPLESCFRP Mold-Complex Shape57 CFRP = Carbon Fiber Reinforced PlasticPreferred CFRP Small Composite Layup Mold Designs58 Self Supporting Tool Laminate DesignsCarbon fiber-benzoxazine tool designed with self supporting featuresPhoto courtesy of Airtech InternationalIntegration of bathtub flanges and return flanges in primary tool laminate design eliminate the need for substructure in smaller size moldsPhoto courtesy of Abaris Training 59 Composite Tubular Structure60 Integrally-Stiffened Tool Laminate61 CFRP Laminate Layup MoldNote rolled laminate edges (flanges) and minimal custom CFRP substructure with torsion resistant cross-grid designPhoto courtesy of Coast Composites -Ascent Aerospace.

7 O Lightweight o Heats/cools rapidly o Low CTE62 BMI Carbon Fiber Duratool 63 BMI = Bismaleimide resin systemHexcel Random Fiber BMI HexTool 64C-17 Tailcone (Mandrel & Final Part)65 Integrated Composite System (ICS) with C-Foam Interior66 Machining of C-Foam UnderstructurePrepreg carbon fiber reinforced epoxy or BMI is used to cover the C-Foam, cured, then machined to tool surfaceRough-cut surfaceFinish-cut offset surface prior to prepregPhotos courtesy of Touchstone Research Lab, Ltd67 Machined CFRP/Carbon Foam MoldInternal Mold Line (IML) Beaded Stringer tool68 CFRP/C-Foam Production MoldFinished carbon foam-carbon prepreg machined mold surface prepared with sealer and release agentPhoto courtesy of Touchstone Research Lab, LtdAdvantages: Easily machined to net or corrected shapeLow CTE69 C-FOAM Structural Foam70C-FOAM Production ToolingNote uniform cross-section thickness 7172 MASTER MODEL Tooling ASPECTSCNC Machined Tooling Board ModelMachining F-35 Nacelle Master ModelPhoto courtesy of Process Fab, board assembly:Planks are bonded together as need to near net shape prior to machiningPhoto courtesy of Coastal Enterprises73 Legacy Master Model Fabrication.

8 Rigged-Template/Splined ModelTemplates were hand cut and filed from photo-sensitive aluminum stock transferred from master Mylar's on a light station templates rigged to framework, caged, and splined using epoxy resin paste or gypsum based Tooling China 2017 - Tooling and Mold Technology for Composites ManufacturingLegacy Marine Plug FabricationPlywood or pressed-board frames with batten wood cover Machined Tooling Block ModelNote the adhesive lines between the planks in the machined model have a difference in CTEP hoto courtesy of General Plastics Manufacturing block surfaces must be sealed and released prior to Tooling Block Master(Low CTE Master Model Material)Photo courtesy of CompotoolCeramic Tooling block comes in medium and high density versions and services 500 F (260 C)77 Photos courtesy of Composite solutions CorporationCAD Part-FileMachined Master ModelFinal Kevlar/Epoxy Part made from the Layup MoldTrimmed & Drilled in TDFTrim & Drill Fixture (TDF) from MMCFRP Layup Mold from MMExample.

9 Master Model-Tool FamilyCAD Tool Design & Fab7879 RUBBER & ELASTOMER, BAGGING TOOLINGR eusable Vacuum Bags (RVB)80 Large Reusable Silicone Rubber Vacuum Bag81 Tooling SUPPORT STRUCTURES FOR MANUFACTURING82 Modern Composite Eggcrate DesignPhoto courtesy of Janicki ManufacturingPhoto courtesy Coast Composites /AscentUses same material for substructure as for tool face to eliminate CTE mismatchNote torsion box design below83 Truss/Torsion Eggcrate DesignPhoto/images courtesy of Burnham Composite StructuresBurnham fabricates "Ready-to Assemble" Cut are Waterjet cut to desired dimensions as specified by customer's supplied CAD data and / or trend is to provide torsion stability and minimize depth of substructure84 Composite Tubular/Truss StructuresSource.

10 Burnham CompositesSquare tubes, angles, columns and gussets that can be cut to size, bonded and fastened together to provide a cradle structure Source: Leading Edge Aerospace85 Composite LM w/Aluminum FrameCourtesy of the Advanced Composite Group, LTD (Cytec)Composite LM rests in aluminum cradle/workstandNote in-plane pad-to-frame features allowing for free-floating tool laminate to prevent effect of CTE mismatchUtilizes galvanic (glass) barrier between CF and aluminum86 Invar Tube Frame SubstructureCompare weight to conventional Invar eggcrate designImage courtesy of Re-Steel, Inc87 Conventional Egg-crate DesignNote: Air circulation and lightening holes cutout in the honeycomb sandwich egg crate structure88 Composite Tool w/Aluminum Frame89 Low-Cost Spar & Stringer Molds90 MISCELLANEOUS Tooling TECHNOLOGIES91 Aluminum Clamshell Mold for ViolinMachined aluminum clamshell molds for violin bodyCourtesy of Zach Wing, Ceramics Manufacturing92 Invar Layup MoldPhoto courtesy of Coast Composites -Ascent AerospaceAdvantages: o Durable and long-lasting production capabilitieso Low CTE93 Machined Monolithic Graphite MoldsPhoto courtesy of Electro Tech MachiningTrue Graphite toolingPhoto courtesy of Turnpoint DesignAdvantages.