US 12,459,163 B2
Method of making a composite mould tool and repairing method of a composite mould tool
John Chippendale, Blackburn (GB)
Assigned to BAE Systems plc, London (GB)
Appl. No. 18/567,438
Filed by BAE Systems plc, London (GB)
PCT Filed Jun. 15, 2022, PCT No. PCT/GB2022/051513
§ 371(c)(1), (2) Date Dec. 6, 2023,
PCT Pub. No. WO2022/263825, PCT Pub. Date Dec. 22, 2022.
Claims priority of application No. 21275085 (EP), filed on Jun. 18, 2021; and application No. 2108724 (GB), filed on Jun. 18, 2021.
Prior Publication US 2024/0269900 A1, Aug. 15, 2024
Int. Cl. B29C 33/38 (2006.01); B29C 33/56 (2006.01); B29C 33/74 (2006.01); B29L 31/00 (2006.01); C22C 38/08 (2006.01); C23C 24/04 (2006.01); B29C 70/30 (2006.01)
CPC B29C 33/38 (2013.01) [B29C 33/3857 (2013.01); B29C 33/56 (2013.01); B29C 33/74 (2013.01); B29C 2033/3864 (2013.01); B29C 70/30 (2013.01); B29L 2031/757 (2013.01); C22C 38/08 (2013.01); C23C 24/04 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method of manufacturing a composite mould tool, the method comprising:
obtaining a mould tool precursor having a first face and a reverse second face, wherein the precursor comprises and/or is a first metal, wherein the precursor comprises a perforation extending between the first face and the second face (S101);
hermetically sealing the precursor by cold spraying a layer on the second face using particles comprising and/or of a second metal, wherein the respective coefficients of thermal expansion of the first metal and the second metal are within a factor of 5, wherein the layer does not have any perforations therethrough and wherein the precursor is the mould tool before the layer is cold sprayed on the second face (S102); and
providing a faceplate of the composite mould tool by subtractive manufacturing of the first face (S103);
thereby manufacturing the mould tool having the faceplate provided by subtractive manufacturing of the first face and the reverse second face hermetically sealed by cold spraying the layer thereon.