METHOD OF MANUFACTURING A PRESSURE INTENSIFYING TOOL AND TOOL PRODUCED THEREBY

• US 20070073433A1
• Filed: 09/23/2005
• Published: 03/29/2007
• Est. Priority Date: 09/23/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Froeschner, Neal, Piszar, Jim
• Granted Patent: US 7,496,424 B2
• Time in Patent Office: Days
• US Class Current: 700/119
• CPC Class Codes: B33Y 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49003 Make two halves of tool, model at the same time
• CPC Class Codes: G05B 2219/49011 Machine 2-D slices, build 3-D model, laminated object manufacturing LOM
• CPC Class Codes: G05B 2219/49013 Deposit layers, cured by scanning laser, stereo lithography SLA, prototyping
• CPC Class Codes: G05B 2219/49017 DTM desktop manufacturing, prototyping
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A tool used to direct the pressure applied to features of a plastic laminate part layup during co-curing or co-bonding is manufactured using direct digital manufacturing techniques. A CAD drawing representing the tool is generated and converted into digital data file suitable for controlling the operation of a rapid prototyping machine. The tool is formed in the rapid prototyping machine by additive layering of material until the features and dimensions of the layered material correspond to the CAD drawing. The resulting tool exhibits geometries and dimensions virtually identical to the theoretical dimensions of the CAD model of the tool.

Claims

1. A method of manufacturing a tool used to direct pressure applied to areas of a plastic laminate part during co-curing or co-bonding, comprising the steps of:

(A) generating a digital data file representing a three dimensional model of the tool; and

,

(B) using the digital data file to direct automated manufacturing of the tool in which additive layers of material are successively formed until the features of the tool correspond to the three dimensional model, wherein the three dimensional model includes separate complementary pieces each having a surface for engaging and intensifying the pressure applied to the part.

2. The method of claim 1, wherein step (A) includes creating a CAD model of the tool.

3. The method of claim 2, wherein step (A) includes converting the CAD model to an STL file format.

4. The method of claim 3, wherein step (A) includes using the STL formatted file to generate a slice file representing a plurality of spaced cross sections of the three dimensional model.

5. The method of claim 1, wherein step (B) is performed using a rapid prototype machine automatically controlled by the digital data file.

6. The method of claim 1, wherein the additive layers are formed using one of the following manufacturing techniques:

a) stereolithography,

b) laminated object manufacturing,

c) selective laser sintering,

d) fused deposition modeling,

e) solid ground curing,

f) three dimensional ink-jet printing.

7. The method of claim 1, including the step of finishing surfaces of the tool to obtain desired surface characteristics.

8. The method of claim 1, wherein step (A) includes integrally forming features in the three dimensional model used in co-curing or co-bonding the part.

9. (canceled)

10. A tool used to direct the pressure applied to features of a plastic laminate part during co-curing or co-bonding of the part, manufactured by:

(A) generating a CAD drawing representing the tool and wherein the tool comprises a relief for allowing the tool to flex during the co-curing or co-bonding;

(B) producing a digital data file corresponding to the CAD drawing; and

,

(C) using the digital data file to control the operation of a rapid prototype manufacturing machine, wherein the tool is formed by additive layering of material in the machine until the features and dimensions of the layered material correspond to the CAD drawing.

11. The method of claim 10, wherein step (B) includes converting the digital data file to an STL file format, and using the STL formatted file to generate a slice file representing a plurality of spaced cross sections of the CAD drawing.

12. The method of claim 10, including the step of finishing surfaces of the tool to obtain desired surface smoothness.

13. The method of claim 10, wherein the relief comprises an elongated slot provided in the tool.

14. The method of claim 10, wherein step (A) includes forming a dam for limiting the movement of constituents of the laminate during the co-curing or co-bonding.

15. A tool for directing the compaction pressure applied to a layup of laminate plies during co-curing or co-bonding, comprising the steps of:

(A) generating a digital data file representing the features and dimensions of the tool, wherein the tool comprises a pair of tool members and an elongated dam provided on one of the tool members for limiting the movement of constituents of the laminate during the co-curing or co-bonding; and

,

(B) additively layering materials under automatic control by the digital data file to form the tool.

16. The method of claim 15, wherein step (A) includes:

generating a CAD drawing of the tool,

converting the CAD drawing into a file format suitable for automatically controlling the operation of a machine for additively layering the materials.

17. The method of claim 15, wherein step (B) is performed by fused deposition modeling.

18. The method of claim 15, wherein generating the CAD drawing includes generating at least two drawings respectively corresponding to the two tool members of the tool.

19. The method of claim 15, wherein step (B) is using a digitally controlled rapid prototype machine controlled by the digital data file.

20. The method of claim 15, wherein step (B) includes integrally forming a surface feature on the tool through which pressure may be applied to the tool by a bagging case.