New Materials for Rapid and Economical Composite Toolmaking

Machining metals to the proper dimensions and surface characteristics is a time consuming and expensive part of traditional production toolmaking. A new type of polymer-modified ceramic material is proposed for fabricating high-performance prototypecomposite tooling. The proposed research explores the feasibility of modifying thermally stable composite matrix resins with UV light-curable components to rapidly produce new tools with ceramic-like facing. The program objective is to develop a processfor fabricating high performance composite tools at a fraction of the cost and time required for production tools. The new materials will be compatible with state-of-the-art robotic material placement technology. The cure conditions for the toolingcomposite matrix resin will be mild enough to allow actual parts to be used as templates. When post-cured, the new tools will allow multiple runs with high temperature-curing matrix resins such as bismaleides. The CTE of the composite tools can bematched to the intended use by variation of the tool's matrix resin composition. In the proposed study, the methodology for preparing these novel composites will be developed and demonstrated. The new resins could potentially be used in a variety ofcomposite fabrication and specialty coating processes to reduce costs and improve composite properties.The benefits of inexpensive, rapid prototype tool fabrication for the short-run production of complex composite parts, include: controllable CTE, easyintegration with computer-controlled tool fabrication technology, and durability with high-temperature-curing composite matrix resins. Potential commercial applications lie in the manufacture of aerospace, marine and terrestrial vehicles for both militaryand civilian markets.