METHOD OF MANUFACTURING CO-MOLDED INSERTS

• US 20100121475A1
• Filed: 11/13/2008
• Published: 05/13/2010
• Est. Priority Date: 11/13/2008
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Lyons, Brett I.
• Granted Patent: US 8,383,028 B2
• Time in Patent Office: Days
• US Class Current: 700/119
• CPC Class Codes: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 156/1052 with cutting, punching, tearing or severing

Abstract

A method for manufacturing a co-molded insert part for use in composite, plastic, or metal parts is disclosed. The method comprises the step of providing a three-dimensional molding insert produced by a layer additive manufacturing process. The method further comprises the step of applying a layer material in contact with at least a portion of the molding insert. The method further comprises the step of co-molding the layer material and the molding insert simultaneously to produce a co-molded insert part.

Claims

1. A method of manufacturing a co-molded insert part comprising the steps of:

providing a three-dimensional molding insert produced by a layer additive manufacturing process;

applying a layer material in contact with at least a portion of the molding insert; and

,

co-molding the layer material and the molding insert simultaneously to produce a co-molded insert part.

2. The method of claim 1, wherein the molding insert and the layer material are bonded in the co-molding step.

3. The method of claim 1, wherein the layer additive manufacturing process is selected from the group comprising selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography, and three-dimensional printing (3DP).

4. The method of claim 1, wherein the molding insert is comprised of a composite material including a polymer.

5. The method of claim 4, wherein the polymer is one of reinforced and non-reinforced.

6. The method of claim 5, wherein the molding insert is used in fabricating a high stiffness, thin-walled, component part.

7. The method of claim 1, wherein the molding insert is comprised of one or more materials that are compatible with a co-molding process.

8. The method of claim 1, wherein the co-molding step includes a co-molding process selected from the group comprising curing, thermoforming, resin infusion, liquid molding, autoclave molding, compression molding, chemical molding, fiber reinforced plastic (FRP) molding, and pressure forming.

9. The method of claim 1, wherein the layer material is selected from the group consisting of a reinforced thermoplastic laminate, a fiber reinforced plastic, dry carbon fiber, pre-impregnated carbon fiber fabric, thermoset resin, thermoplastic, fabric, fiberglass, polyetherimide (PEI), poly paraphenylene terephthalamide, a light, strong para-aramid synthetic fiber, or a combination thereof.

10. An aerospace part manufactured according to the method to claim 1.

11. An aircraft including the aerospace part of claim 10.

12. A method for additive manufacturing of a co-molded insert part comprising the steps of:

creating with a computer aided design software a three-dimensional computer rendering of an insert part;

transferring the computer rendered insert part to an additive manufacturing machine software to build the insert part;

building the insert part with an additive manufacturing process;

assembling the insert part with a layer material in a mold;

co-molding the insert part and the material in the mold to form a co-molded insert part;

curing the co-molded insert part;

removing the co-molded insert part from the mold; and

,

finishing and post-processing the co-molded insert part.

13. The method of claim 12 wherein the additive manufacturing process is selected from the group comprising selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography, and three-dimensional printing (3DP).

14. The method of claim 12 wherein the layer material is selected from the group consisting of a reinforced thermoplastic laminate, a fiber reinforced plastic, dry carbon fiber, pre-impregnated carbon fiber fabric, thermoset resin, thermoplastic, fabric, fiberglass, polyetherimide (PEI), poly paraphenylene terephthalamide, a light, strong para-aramid synthetic fiber, or a combination thereof.

15. The method of claim 12 wherein the co-molded insert part is used in fiber reinforced or thermoformed plastic parts.

16. The method of claim 12 wherein the co-molding step includes a co-molding process selected from the group comprising thermoforming, resin infusion, liquid molding, autoclave molding, compression molding, chemical molding, fiber reinforced plastic (FRP) molding, and pressure forming.

17. The method of claim 12 wherein the insert part and the layer material are bonded in the co-molding step.

18. A method of manufacturing composite parts having co-molded inserts, wherein three-dimensional computer aided design software is transferred to additive manufacturing machine software, and further wherein processed geometry data and a molding insert producing device forms in a layer-wise fashion, followed by post-processing and inserting the molding insert into a mold.

19. The method of claim 18 wherein the composite parts are aerospace parts used in aircraft and spacecraft.

20. The method of claim 18 wherein the molding insert producing device comprises an additive manufacturing machine.