Smart Tooling TPMC Injection Molding

Fiber reinforced thermoplastic matrix composites (TPMCs) provide unique advantages over thermoset composites for missile structures. However, autoclave and compression molding techniques can only produce fairly simple geometric structures. Limitations inherent to traditional tooling techniques mean that the best that can be achieved for TPMC parts is to make the component in sections and then join these sections through a complex process. To obtain the economy and performance of TPMC for missile structures, the Army needs innovative manufacturing techniques that will allow producing TPMC components in complex shapes. Cornerstone Research Group Inc. (CRG), joining with CRGs Smart Tooling subsidiary, Spintech LLC, proposes to implement Smart Tooling technology for TPMC injection molding, to obtain economical continuous-fiber TPMC components with complex shapes for missile. The benefit of the Smart Tooling approach is that it overcomes the limitations of trapped tooling and offers a low-force extraction, fast-cycle-time methodology for complex and trapped geometry components. This approach will give the Army continuous fiber missile components with improved damage tolerance, faster processing and assembly, and reduced joint weight at lower cost and faster rate than alternative production methods. This technology will have application for other military and commercial components as well.