Abstract: A tooling mandrel for manufacturing a composite structure may include a mandrel body having a fluid passage network formed within the mandrel body for passing a fluid medium through the mandrel body. The fluid passage network may have a passage cross-sectional area shaped to promote thermal conductance between the fluid medium and the tooling mandrel and cause a change in a mandrel cross-sectional shape.

Abstract: A system for fabricating an object includes an additive manufacturing apparatus configured to build a three dimensional (3D) tool by additively depositing two or more layers of material. The system includes a deposition apparatus configured to deposit at least one metal on the 3D tool to form the object on the 3D tool. The system includes a burnout apparatus configured to heat the 3D tool to remove the 3D tool from the object.

Abstract: A tooling mandrel for manufacturing a composite structure may include a mandrel body having a fluid passage network formed within the mandrel body for passing a fluid medium through the mandrel body. The fluid passage network may have a passage cross-sectional area shaped to promote thermal conductance between the fluid medium and the tooling mandrel and cause a change in a mandrel cross-sectional shape.

Abstract: A reconfigurable modular tooling system is provided that approximates the contour of a workpiece to be formed by adjusting the height of an array of pins, each of which represents the contour of the workpiece at that point. A flexible sheet is supported by the pins such that movement of the pins into their contoured position adjusts the flexible sheet forming a mold for a composite part to be manufactured. The modular tooling unit is comprised of a hard rubber which functions to lock the array of pins in position. The locking function of the pins is obtained when the pins are rotated in apertures that match the shape of the pins within the hard rubber tooling unit which distorts the shape of the apertures and locks the pin in position.

Abstract: A method of forming composite parts that consist of the steps of generating a part design in a computer graphics system, positioning an array of rubber blocks having an array of apertures with slidable pins therein and locking the rubber blocks together on a servo drive mechanism forming a tooling fixture. The array of pins has a flexible face sheet connected to them such that the array of pins is adjusted to form the face sheet to approximate the contour of the composited part to be manufactured. The tooling module is then removed from the base servo drive mechanism and used as a mold in an autoclave for cutting composite materials.

Abstract: An apparatus and method for approximating a workpiece contour. The conformable tool includes a support plate having a plurality of apertures and a two dimensional arrangement of a plurality of pins, each of which is slidably disposed within a corresponding aperture of the support plate. A plurality of locking members works in concert to simultaneously lock the plurality of pins in position once the pins have effectively approximated the contour. The conformable tool is pressed against the three dimensional contour of the workpiece so that each pin is displaced in response to the workpiece contour. The pins are then simultaneously locked in place by the locking members and the conformable tool is removed from the workpiece contour so that the conformable tool can be used as a forming base to reproduce the workpiece surface.