Method for making freeform-fabricated core composite articles
First Claim
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1. A method for creating a freeform-fabricated core composite article comprising the steps of:
- a. creating a freeform-fabricated core having an exterior surface structure and an interior structure from freeform material, said freeform material being a material having a transition temperature of at least higher than the intended curing temperature of the freeform-fabricated core article, said interior structure having at least one structural pattern located therein, with a freeform-fabrication machine from a three-dimensional design generated by a computer of the freeform-fabricated core, wherein the freeform-fabricated core is dimensionally accurate;
b. preparing a plurality of composite skins for mating with the exterior surface structure of the freeform-fabricated core;
c. mating the plurality of composite skins to the exterior surface structure of the freeform-fabricated core forming a composite lay-up;
d. disposing a vacuum bag over the composite lay-up forming a cavity between the vacuum bag and the composite lay-up;
e. evacuating the cavity to urge the vacuum bag against the plurality of composite skins thereby compressing the plurality of composite skins against the exterior surface structure of the freeform-fabricated core preventing displacement of the composite skins; and
f. curing the composite lay-up to form the freeform-fabricated core composite article.
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Abstract
A method for making freeform-fabricated core composite articles using freeform-fabricated machine. The articles are capable of being utilized as end products rather than prototype models by creating a core having an interior structure to provide strength to the core and to enhance the strength to weight ratio of the article.
137 Citations
115 Claims
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1. A method for creating a freeform-fabricated core composite article comprising the steps of:
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a. creating a freeform-fabricated core having an exterior surface structure and an interior structure from freeform material, said freeform material being a material having a transition temperature of at least higher than the intended curing temperature of the freeform-fabricated core article, said interior structure having at least one structural pattern located therein, with a freeform-fabrication machine from a three-dimensional design generated by a computer of the freeform-fabricated core, wherein the freeform-fabricated core is dimensionally accurate;
b. preparing a plurality of composite skins for mating with the exterior surface structure of the freeform-fabricated core;
c. mating the plurality of composite skins to the exterior surface structure of the freeform-fabricated core forming a composite lay-up;
d. disposing a vacuum bag over the composite lay-up forming a cavity between the vacuum bag and the composite lay-up;
e. evacuating the cavity to urge the vacuum bag against the plurality of composite skins thereby compressing the plurality of composite skins against the exterior surface structure of the freeform-fabricated core preventing displacement of the composite skins; and
f. curing the composite lay-up to form the freeform-fabricated core composite article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method for creating a freeform-fabricated core composite article comprising the steps of:
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a. designing a freeform-fabricated core having an exterior surface structure and an interior structure from freeform material, said freeform material being a material having a transition temperature of at least higher than the intended curing temperature of the freeform-fabricated core article, said interior structure having at least one structural pattern located therein, for the freeform-fabricated core composite article for fabrication with a freeform-fabrication machine, with a three-dimensional design generated by a computer of the freeform-fabricated core, wherein the three-dimensional design generated by a computer of the freeform-fabricated core is dimensionally accurate;
b. fabricating the freeform-fabricated core with the freeform-fabrication machine and the fabrication material from the three-dimensional design generated by a computer of the freeform-fabricated core such that the freeform fabrication machine cooperates with the fabrication material to fabricate the freeform-fabricated core on substantially a layer by layer basis;
c. preparing the fabricated freeform-fabricated core for mating with a plurality of composite skins;
d. preparing the plurality of composite skins for mating with the exterior surface of the freeform-fabricated core, the plurality of composite skins comprises fibrous reinforcement material disposed in a binding matrix;
e. mating the plurality of composite skins to the exterior surface structure of the freeform-fabricated core forming a composite lay-up;
f. disposing a vacuum bag over the composite lay-up forming a cavity between the vacuum bag and the composite lay-up;
g. evacuating the cavity to urge the vacuum bag against the plurality of composite skins thereby compressing the plurality of composite skins against the exterior surface structure of the freeform-fabricated core preventing displacement of the plurality of composite skins and removing excess binding matrix from the plurality of composite skins; and
h. curing the composite lay-up to form the freeform-fabricated core composite article. - View Dependent Claims (24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48)
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49. A method for creating a freeform-fabricated core composite article comprising the steps of:
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a. designing a freeform-fabricated core having an exterior surface structure and an interior structure from freeform material, said freeform material being a material having a transition temperature of at least higher than the intended curing temperature of the freeform-fabricated core article, said interior structure having at least one structural pattern located therein, for the freeform-fabricated core composite article with a three-dimensional computer aided design program to create a software file of a three-dimensional design generated by a computer of the freeform-fabricated core, wherein the three-dimensional design generated by a computer of the freeform-fabricated core is dimensionally accurate;
b. modifying the software file of the three-dimensional design generated by a computer of the freeform-fabricated core to allow for a plurality of composite skins to be attached to the exterior surface structure of the freeform-fabricated core by reducing the exterior dimensions of the freeform-fabricated core to compensate for the thickness of the plurality of composite skins such that the freeform-fabricated core and the plurality of composite skins cooperate to provide the desired exterior dimension of the freeform-fabricated core composite article;
c. exporting the modified software file of the three-dimensional design generated by a computer of the freeform-fabricated core into a machine language software file of the freeform-fabricated core;
d. importing the machine language software file of the freeform-fabricated core into a computer workstation, the computer workstation being of the type which produces control signals that control a freeform fabrication machine, the freeform fabrication machine having a build platform situated in a fabrication material storage area which holds fabrication material, the fabrication material being capable of cooperating with the freeform-fabrication machine to fabricate the freeform-fabricated core;
e. processing the machine language software file of the freeform-fabricated core by the computer workstation to create a freeform fabrication software file that contains a plurality of contiguous planar cross-sectional layers of the freeform-fabricated core to allow the freeform-fabricated core to be fabricated by the freeform fabrication machine on substantially a layer by layer basis;
f. fabricating the freeform-fabricated core with the freeform-fabrication machine and fabrication material from the freeform-fabrication software file in the computer workstation such that the combination of the freeform-fabrication software file, the computer workstation, the freeform-fabrication machine and the fabrication material cooperate to fabricate the freeform-fabricated core on substantially a layer by layer basis on the build platform;
g. removing the fabricated freeform-fabricated core from the build platform of the freeform-fabrication machine;
h. cleaning the freeform-fabricated core to remove any contaminants and any sacrificial build support material that may exist from the freeform-fabricated core;
i. curing the freeform-fabricated core;
j. finishing the cured freeform-fabricated core, wherein the imperfections, blemishes or excess cured fabrication material are eliminated from the freeform-fabricated core;
k. cutting the plurality of composite skins into a predetermined pattern wherein the pattern of the plurality of composite skins mates with the exterior surface structure of the freeform-fabricated core, the plurality of composite skins comprises fibrous reinforcement material disposed in a binding matrix;
l. mating the plurality of composite skins to the exterior surface structure of the freeform-fabricated core forming a composite lay-up;
m. disposing a vacuum bag assembly over the composite lay-up, the vacuum bag assembly comprising a vacuum bag, a separator film, a breather ply, and a vacuum pump where the separator film is disposed over the composite lay-up, the breather ply is disposed over the separator film, and the vacuum bag is disposed over the breather ply forming a plurality of cavities between the vacuum bag and the composite lay-up;
n. evacuating the plurality of cavities between the vacuum bag and the composite lay-up with the vacuum pump to urge the vacuum bag against the breather ply, to urge the breather ply against the separator film, to urge the separator film against the plurality of composite skins thereby compressing the plurality of composite skins against the exterior surface structure of the freeform-fabricated core preventing displacement of the plurality of composite skins and removing excess binding matrix from the plurality of composite skins;
o. curing the composite lay-up, wherein the composite lay-up is subjected to external stimulus that solidifies and hardens the composite lay-up forming a cured composite lay-up; and
p. finishing the cured composite lay-up, wherein the imperfections, blemishes or excess cured binding matrix are eliminated from the cured composite lay-up forming the freeform-fabricated core composite article. - View Dependent Claims (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115)
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Specification