Abstract: A method and tooling concept for fabricating complex composite parts is provided. The method and tooling concept use various tooling configurations in order to produce varying magnitudes of thermal expansion at different areas within the tooling concept. The varying magnitudes of thermal expansion allow the tool concept to account for varying magnitudes of tool movement needed to debulk and consolidate varying thickness areas of the composite workpiece being cured. The tooling concept is formed of different materials having different thicknesses that allow the tooling concept to produce varying magnitudes of thermal expansion. The exterior surface of the tooling concept is covered by a compliant covering. The compliant covering helps to equalize the consolidation pressures produced by the tooling concept during curing. A composite wing box structure fabricated using the method and tooling concept is also disclosed.

Abstract: An method and tooling concept for fabricating complex composite parts is provided. The method and tooling concept use various tooling configurations in order to produce varying magnitudes of thermal expansion at different areas within the tooling concept. The varying magnitudes of thermal expansion allow the tool concept to account for varying magnitudes of tool movement needed to debulk and consolidate varying thickness areas of the composite workpiece being cured. The tooling concept is formed of different materials having different thicknesses that allow the tooling concept to produce varying magnitudes of thermal expansion. The exterior surface of the tooling concept is covered by a compliant covering. The compliant covering helps to equalize the consolidation pressures produced by the tooling concept during curing. A composite wing box structure fabricated using the method and tooling concept is also disclosed.