Methods for forming thermoplastic parts with freeform tooling
First Claim
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1. A method of prototyping a thermoplastic composite part, the method comprising:
- three-dimensional printing (3DP) discardable freeform tooling elements consisting of a soluble mold comprised of a first portion and a second portion, and a soluble core, wherein the soluble mold and the soluble core are solid and consist of a soluble ceramic material, the soluble ceramic material consisting of powdered aluminous silica with silicate and polymer binder;
heating a first prepreg sheet and a second prepreg sheet in a heating element, until the first prepreg sheet and the second prepreg sheet are pliable;
forming a stamp form part assembly comprising, in succession, the first portion of the soluble mold, the first prepreg sheet that is pliable, the soluble core, the second prepreg sheet that is pliable, and the second portion of the soluble mold, wherein the first prepreg sheet forms around contours of a first molded side of the first portion of the soluble mold and around a bottom portion of the soluble core, and further wherein the second prepreg sheet forms around contours of a first molded side of the second portion of the soluble mold and around a top portion of the soluble core;
stamp forming the stamp form part assembly in a stamp forming apparatus using a thermoplastic part forming process comprising a thermoplastic stamp forming process to form thermoplastic composite materials into the thermoplastic composite part, the soluble core being internal to the thermoplastic composite part; and
separating the thermoplastic composite part from the soluble mold, and removing the soluble core from the thermoplastic composite part through dissolution.
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Abstract
In an embodiment of the disclosure, there is provided a method of prototyping a thermoplastic composite part. The method comprises fabricating one or more discardable freeform tooling elements via a rapid manufacturing process. The method further comprises forming thermoplastic composite materials into a thermoplastic composite prototype part using the one or more discardable freeform tooling elements. The method further comprises separating the thermoplastic composite prototype part from the one or more discardable freeform tooling elements.
23 Citations
20 Claims
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1. A method of prototyping a thermoplastic composite part, the method comprising:
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three-dimensional printing (3DP) discardable freeform tooling elements consisting of a soluble mold comprised of a first portion and a second portion, and a soluble core, wherein the soluble mold and the soluble core are solid and consist of a soluble ceramic material, the soluble ceramic material consisting of powdered aluminous silica with silicate and polymer binder; heating a first prepreg sheet and a second prepreg sheet in a heating element, until the first prepreg sheet and the second prepreg sheet are pliable; forming a stamp form part assembly comprising, in succession, the first portion of the soluble mold, the first prepreg sheet that is pliable, the soluble core, the second prepreg sheet that is pliable, and the second portion of the soluble mold, wherein the first prepreg sheet forms around contours of a first molded side of the first portion of the soluble mold and around a bottom portion of the soluble core, and further wherein the second prepreg sheet forms around contours of a first molded side of the second portion of the soluble mold and around a top portion of the soluble core; stamp forming the stamp form part assembly in a stamp forming apparatus using a thermoplastic part forming process comprising a thermoplastic stamp forming process to form thermoplastic composite materials into the thermoplastic composite part, the soluble core being internal to the thermoplastic composite part; and separating the thermoplastic composite part from the soluble mold, and removing the soluble core from the thermoplastic composite part through dissolution. - View Dependent Claims (2, 3, 4, 6, 7, 8, 9, 10, 11)
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5. A method of prototyping a thermoplastic composite part, the method comprising:
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three-dimensional printing (3DP) discardable freeform tooling elements comprising a soluble mold comprised of a first portion and a second portion, and a soluble core, wherein the soluble mold and the soluble core are solid and consist of a soluble ceramic material, the soluble ceramic material consisting of powdered aluminous silica with silicate and polymer binder; heating a first prepreg sheet and a second prepreg sheet in a heating element, until the first prepreg sheet and the second prepreg sheet are pliable; forming a stamp form part assembly comprising, in succession, the first portion of the soluble mold, the first prepreg sheet that is pliable, the soluble core, the second prepreg sheet that is pliable, and the second portion of the soluble mold, wherein the first prepreg sheet forms around contours of a first molded side of the first portion of the soluble mold and around a bottom portion of the soluble core, and further wherein the second prepreg sheet forms around contours of a first molded side of the second portion of the soluble mold and around a top portion of the soluble core; stamp forming the stamp form part assembly in a stamp forming apparatus using a thermoplastic part forming process comprising a thermoplastic stamp forming process to form thermoplastic composite materials into the thermoplastic composite part, the soluble core being internal to the thermoplastic composite part, and the stamp forming apparatus applying a pressure to the stamp form part assembly in a range of from 100 psi (pounds per square inch) to 900 psi; and separating the thermoplastic composite part from the mold and removing the soluble core from the thermoplastic composite part through dissolution.
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12. A method of prototyping a fiber-reinforced thermoplastic composite part, the method comprising:
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generating a three-dimensional computer-aided design (3D CAD) model of discardable tooling elements for a prototype part; three-dimensional printing (3DP) discardable freeform tooling elements based on the 3D CAD model, the discardable freeform tooling elements consisting of a soluble mold comprised of a first portion and a second portion, and a soluble core, wherein the soluble mold and the soluble core are solid and consist of a soluble ceramic material, the soluble ceramic material consisting of powdered aluminous silica with silicate and polymer binder; heating a first prepreg sheet and a second prepreg sheet in a heating element, until the first prepreg sheet and the second prepreg sheet are pliable; forming a stamp form part assembly comprising, in succession, the first portion of the soluble mold, the first prepreg sheet that is pliable, the soluble core, the second prepreg sheet that is pliable, and the second portion of the soluble mold, wherein the first prepreg sheet forms around contours of a first molded side of the first portion of the soluble mold and around a bottom portion of the soluble core, and further wherein the second prepreg sheet forms around contours of a first molded side of the second portion of the soluble mold and around a top portion of the soluble core; stamp forming the stamp form part assembly in a stamp forming apparatus using a thermoplastic part forming process comprising a thermoplastic stamp forming process, to form fiber-reinforced thermoplastic composite materials into the fiber-reinforced thermoplastic composite part; separating the fiber-reinforced thermoplastic composite part from the soluble mold and removing the soluble core from the fiber-reinforced thermoplastic composite part through dissolution; and discarding the discardable freeform tooling elements. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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Specification