New Materials for Rapid and Economical Composite Tool Making

An innovative solution for inexpensively fabricating small numbers of composite parts is proposed. Since the unit costs associated with traditional production toolmaking are extremely high for small runs, this innovation makes possible low cost prototypesand low cost replacement parts for aerospace systems. Phase I identified novel thermally stable composite matrix resins which cure under UV light to rapidly produce tools with ceramic-like facing. This resin permits PHOTOMOLDING, the fabrication withlight of high performance composite tools at a fraction of the cost and time required for production tools. Phase I research demonstrated that the low temperature cure conditions of PHOTOMOLDING are mild enough to allow actual parts to be used astemplates. When post-cured, the ceramic-like facing allows multiple runs with high temperature-curing matrix resins such as bismaleimides. Furthermore, unlike metals, the CTE of the composite tools can be matched to the intended use by varying thetool's matrix resin composition. Phase II expands the methodology for preparing these novel composite tools by optimizing materials and by demonstrating a number of practical applications. PHOTOMOLDING is compatible with CAD and advanced robotic fiberplacement technology. Thus it can be used in composite prototyping, injection mold fabrication, carbon-carbon composite tooling and on-aircraft repair.