SAMPE Journal - November/December 2021 - 38
FEATURE
LARGE COMPOSITE
AEROSTRUCTURES
Hybrid Additively Manufactured Tooling for Large
Composite Aerostructures
Scott R. Huelskamp1, Vern Benson2
, and Maria Pilar Muñoz-Lopez3
1University of Dayton Research Institute, Dayton, OH
2Northrop Grumman Innovation Systems, Clearfield, UT
3
Airbus Spain, Madrid, Spain
E-Mail: scott.huelskamp@udri.udayton.edu
ABSTRACT
A
dditively manufactured (AM) tooling has been shown to reduce cost
and time in composite fabrication. However, AM tooling suffers from
high, anisotropic thermal expansion that makes molding high accuracy
composite parts at high temperatures very difficult. This is especially true
for large structures with high aspect ratios and complex surface features.
This paper discusses a new approach to overcome this challenge and allows
AM tooling to be used in previously infeasible applications. A sandwich
tool approach, made with a combination of a polymeric AM core and
conventional tooling prepreg facesheets, was used to take advantage of
the inherent strengths of each material while offsetting for the weaknesses.
This approach was ultimately demonstrated on a multi-piece C-spar tool
in support of an Airbus tooling development program. The tool exhibited
isotropic thermal expansion that was nearly equivalent to that of invar at
180 degrees Celsius in both the x and y direction. The tooling was shown
to be durable and dimensionally accurate through more than ten autoclave
cycles.
38 | SAMPE JOURNAL | NOVEMBER/DECEMBER 2021
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SAMPE Journal - November/December 2021
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