US 12,285,920 B2
Method and apparatus for fabrication of composite tooling
Michael J. Fleming, Ladson, SC (US)
Assigned to The Boeing Company, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Sep. 30, 2019, as Appl. No. 16/588,773.
Prior Publication US 2021/0094246 A1, Apr. 1, 2021
Int. Cl. B29C 70/00 (2006.01); B29C 33/38 (2006.01); B29C 70/44 (2006.01); B64F 5/10 (2017.01); B29L 31/00 (2006.01); B29L 31/28 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/44 (2013.01) [B29C 33/3842 (2013.01); B64F 5/10 (2017.01); B29C 2033/385 (2013.01); B29L 2031/28 (2013.01); B29L 2031/3076 (2013.01); B29L 2031/757 (2013.01)] 27 Claims
OG exemplary drawing
 
1. A method of forming a tool having a tooling surface for use to form a mold line in fabrication of composite parts, the method comprising:
conforming a layer to a reference part, the layer having an adhesive side that faces outward from the reference part and a release side that faces the reference part;
adhering a plurality of prefabricated sections to the layer; and
filling a plurality of gaps between the plurality of prefabricated sections with a joining material;
wherein at least part of the release side forms at least part of the tooling surface of the tool;
wherein the conforming the layer to the reference part comprises:
applying a vacuum such that the layer conforms to a surface of the reference part;
wherein the adhering the plurality of prefabricated sections to the layer comprises forming the gaps at portions of the layer that do not adhere to the prefabricated sections; and
wherein adhering the plurality of prefabricated sections to the layer comprises, while applying the vacuum:
positioning the plurality of prefabricated sections over the layer over respective ones of a plurality of flat portions of the reference part, each of the plurality of prefabricated sections physically contacting the layer; and
applying a force to the plurality of prefabricated sections to adhere the plurality of prefabricated sections to the adhesive side of the layer.