8/7/2019 Rapid Prototype Composite Tooling
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Rapid Prototype Composite Tooling Using CFOAM® Carbon Foam
Introduction
Asthe world movesfaster and partsare developed via computer aided design, the old
methodsof buildi ng masters(plugs) and pulling parts has become too slow and costly.
Designerswant to go from a CAD file to a composite part as fast aspossible.
At Touchstone Research Laboratory, there has been a breakthrough in the development of
inexpensive, off-the-shelf coatings providing dimensionally stable, low coefficient of
thermal expansion (CTE), large (and small) rapid prototypesof carbon fiber reinforced
plastics.
Rapid Prototype Composite Tooling Using CFOAM Carbon Foam
Touchstone is currently developing several processesto apply tooling surfacesto CFOAM carbon foam that are suited for prototype tools designed to
make lessthan ten parts. It is an inexpensive processthat can be manufactured quickly.
The “rapid prototype” surfacing concept begins with the
application of a filler material to the top layer of the
foam. The filler material has high use temperatures,suitable compressive strengths, and iseasily machined or
sanded. The purpose of the filler material is to fill the
CFOAM pore structure in order to create the base for a
tool surface that will maintain vacuum integrity during
vacuum bagging on the surface.
High-temperature epoxy paint isthen applied to the fil led
foam surface in a carefully controlled manner in order to
manage the final tolerance that takesinto account the
paint thickness. This system can be seen in the
photomicrographsbelow.
Steps in Making a Rapid Prototype Tool Using CFOAM Carbon Foam
1. BLOCK AND MACHINE: First, panelsof CFOAM are bonded together and
machined to within 0.004" of the desired final geometry of the tool.
2. FILL AND CURE: The filler coat isthen applied to the surface of the machined
foam with a squeegee and adds no measurable thicknesswhen applied andprepared properly. The picture below showsa tool that hasbeen filled. An oven cure
in excessof 350° F istypically performed. A second coating of filler materialscould
be applied and oven cured if required.
Another optional processfor applying a different filler material isto apply it very
liberally over the entire surface of the machined tool, cure it at room temperature
within an hour while the tool ison the mill, and then re-machining the tool to the
finish dimensions. This eliminateshand workand the filler providesa very hard
surface.
3. PRIMER COATING: After the filler material has been completely smoothed,
consistent with the CFOAM carbon foam surface by hand or via machining, a primer
coating isapplied by either spraying or rolling. The primer used istypically part of a
two part epoxy paint that has use temperature of 400° F (204° C). The primer coating
fillsany remaining porosity in the filled CFOAM surface.
After the primer coat isapplied, the surface isready for the second coat of the two part epoxy paint.
Below are two examplesof completed rapid prototype toolswith both coatsof the two part epoxy paint system. The tool on the l eft showsthe masking
paper on the edges. The paint system addsapproximately 0.004” to the surface of the tool.
To date, the rapid prototype tooling surfacesused at Touchstone have been used to successfully cure composite partswhen the tool was vacuum
bagged to a flat table, or the entire tool wasenvelope bagged.
Touchstone has a development plan to expand the robustnessof the rapid prototype surfacesfor autoclave processesand to achieve a vacuum integral
surface.
What We Offer
We currently offer rapid prototype tools built to order.
In addition, Touchstone can manufacture a rapid prototype tool and pull a part . If the part isacceptable, Touchstone can machine away the
prototype surface and replace it with a durable rate tool surface.
We also supply CFOAM carbon foam eith er in panels or machined to shape for our customersto bu ild thei r own tools.
Although our customers are alwaystrying something new, we will provide the best advice we can offer and we do offer on-site consulting and
assistance in dev eloping new composite tooling specifically for your special needs.
For more information about our Rapid Composite Tooling, please call or email usfor a prompt response.
Telephone: 304.547.5800 email: [email protected]
Voice: (304) 547-5800
Fax: (304) 547-5802
Email: [email protected]
CFOAM® isa regi stered trademarko f Touchstone Research Laboratory, Ltd.
CFOAM® productsmay be covered under the following patentswith more patents pending:
6,656,238 - 6,656,239 - 6,689,470 - 6,749,652 - 6,814,765 - 6,833,011 - 6,833,012 -
6,849,098 - 6,860,910 - 6,861,151 - 6,869,455 - 6,899,970 - 7,192,537 - 7,247,368
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