CPC B29C 33/3842 (2013.01) [B29C 33/505 (2013.01); B29C 49/44 (2013.01); B29C 64/10 (2017.08); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); B29L 2031/7172 (2013.01)] | 12 Claims |
1. A method of fabricating a seamless fuel tank, the method comprising:
3D-printing a mold, the mold including a body having a first side wall, a second side wall opposite the first side wall, an inner surface, an outer surface and a nozzle extending outwardly from and supported by the second side wall, the first side wall having a first wall thickness and the second side wall having a second wall thickness that is greater than the first thickness, the outer surface having a concave portion and a convex portion;
connecting a pressure source to the nozzle on the mold;
inflating the mold via the nozzle;
forming a seamless, flexible fuel tank by layering-up a plurality of layers over the outer surface of the inflated mold via additive manufacturing, the flexible fuel tank having a port formed about the nozzle, and the tank surrounding the mold;
deflating the mold; and
withdrawing the mold through the port of the fully formed, flexible fuel tank,
wherein the mold is a male mold, and
wherein the mold is fabricated from a durable and rigid material having a Shore A rating between 20 and 95.
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