US 11,969,960 B2
Cutting wire for removal of expanded material after curing of a composite part
Gary E. Georgeson, Tacoma, WA (US); Xiaoxi Wang, Mukilteo, WA (US); and Jonathan Santiago, Seattle, WA (US)
Assigned to The Boeing Company, Chicago, IL (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Feb. 28, 2022, as Appl. No. 17/682,487.
Application 17/682,487 is a division of application No. 16/448,576, filed on Jun. 21, 2019, granted, now 11,292,208.
Prior Publication US 2022/0176644 A1, Jun. 9, 2022
Int. Cl. B29C 70/44 (2006.01); B29C 45/72 (2006.01); B29C 65/00 (2006.01); B29C 70/54 (2006.01)
CPC B29C 70/446 (2013.01) [B29C 45/7207 (2013.01); B29C 66/0326 (2013.01); B29C 66/727 (2013.01); B29C 66/816 (2013.01); B29C 70/54 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of fabricating a composite part, the method comprising:
placing one or more composite layers on a molding tool to form a layup, wherein at least a portion of the layup is within a constrained space;
activating a foamable material to expand into an expanded material within the constrained space;
curing the layup while the expanded material presses the layup against the molding tool to form the composite part;
boring a hole through the expanded material after curing;
threading a cutting wire through the hole in the expanded material;
controlling a manipulator comprising a robotic arm, with a controller, to perform automated tasks of:
grasping opposing ends of the cutting wire with end effectors that make an electrical coupling with the cutting wire;
heating the cutting wire with current applied through the cutting wire via the electrical coupling; and
moving the cutting wire within the constrained space to cut the expanded material into pieces; and
removing the pieces from the constrained space.