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
www. sampe.org
http://www.sampe.org
SAMPE Journal - November/December 2021
Table of Contents for the Digital Edition of SAMPE Journal - November/December 2021
SAMPE Journal - November/December 2021 - Cover1
SAMPE Journal - November/December 2021 - Cover2
SAMPE Journal - November/December 2021 - 1
SAMPE Journal - November/December 2021 - 2
SAMPE Journal - November/December 2021 - 3
SAMPE Journal - November/December 2021 - 4
SAMPE Journal - November/December 2021 - 5
SAMPE Journal - November/December 2021 - 6
SAMPE Journal - November/December 2021 - 7
SAMPE Journal - November/December 2021 - 8
SAMPE Journal - November/December 2021 - 9
SAMPE Journal - November/December 2021 - 10
SAMPE Journal - November/December 2021 - 11
SAMPE Journal - November/December 2021 - 12
SAMPE Journal - November/December 2021 - 13
SAMPE Journal - November/December 2021 - 14
SAMPE Journal - November/December 2021 - 15
SAMPE Journal - November/December 2021 - 16
SAMPE Journal - November/December 2021 - 17
SAMPE Journal - November/December 2021 - 18
SAMPE Journal - November/December 2021 - 19
SAMPE Journal - November/December 2021 - 20
SAMPE Journal - November/December 2021 - 21
SAMPE Journal - November/December 2021 - 22
SAMPE Journal - November/December 2021 - 23
SAMPE Journal - November/December 2021 - 24
SAMPE Journal - November/December 2021 - 25
SAMPE Journal - November/December 2021 - 26
SAMPE Journal - November/December 2021 - 27
SAMPE Journal - November/December 2021 - 28
SAMPE Journal - November/December 2021 - 29
SAMPE Journal - November/December 2021 - 30
SAMPE Journal - November/December 2021 - 31
SAMPE Journal - November/December 2021 - 32
SAMPE Journal - November/December 2021 - 33
SAMPE Journal - November/December 2021 - 34
SAMPE Journal - November/December 2021 - 35
SAMPE Journal - November/December 2021 - 36
SAMPE Journal - November/December 2021 - 37
SAMPE Journal - November/December 2021 - 38
SAMPE Journal - November/December 2021 - 39
SAMPE Journal - November/December 2021 - 40
SAMPE Journal - November/December 2021 - 41
SAMPE Journal - November/December 2021 - 42
SAMPE Journal - November/December 2021 - 43
SAMPE Journal - November/December 2021 - 44
SAMPE Journal - November/December 2021 - 45
SAMPE Journal - November/December 2021 - 46
SAMPE Journal - November/December 2021 - 47
SAMPE Journal - November/December 2021 - 48
SAMPE Journal - November/December 2021 - 49
SAMPE Journal - November/December 2021 - 50
SAMPE Journal - November/December 2021 - 51
SAMPE Journal - November/December 2021 - 52
SAMPE Journal - November/December 2021 - 53
SAMPE Journal - November/December 2021 - 54
SAMPE Journal - November/December 2021 - 55
SAMPE Journal - November/December 2021 - 56
SAMPE Journal - November/December 2021 - 57
SAMPE Journal - November/December 2021 - 58
SAMPE Journal - November/December 2021 - 59
SAMPE Journal - November/December 2021 - 60
SAMPE Journal - November/December 2021 - 61
SAMPE Journal - November/December 2021 - 62
SAMPE Journal - November/December 2021 - 63
SAMPE Journal - November/December 2021 - 64
SAMPE Journal - November/December 2021 - 65
SAMPE Journal - November/December 2021 - 66
SAMPE Journal - November/December 2021 - 67
SAMPE Journal - November/December 2021 - 68
SAMPE Journal - November/December 2021 - 69
SAMPE Journal - November/December 2021 - 70
SAMPE Journal - November/December 2021 - 71
SAMPE Journal - November/December 2021 - 72
SAMPE Journal - November/December 2021 - 73
SAMPE Journal - November/December 2021 - 74
SAMPE Journal - November/December 2021 - 75
SAMPE Journal - November/December 2021 - 76
SAMPE Journal - November/December 2021 - 77
SAMPE Journal - November/December 2021 - 78
SAMPE Journal - November/December 2021 - 79
SAMPE Journal - November/December 2021 - 80
SAMPE Journal - November/December 2021 - 81
SAMPE Journal - November/December 2021 - 82
SAMPE Journal - November/December 2021 - 83
SAMPE Journal - November/December 2021 - 84
SAMPE Journal - November/December 2021 - 85
SAMPE Journal - November/December 2021 - 86
SAMPE Journal - November/December 2021 - 87
SAMPE Journal - November/December 2021 - 88
SAMPE Journal - November/December 2021 - 89
SAMPE Journal - November/December 2021 - 90
SAMPE Journal - November/December 2021 - 91
SAMPE Journal - November/December 2021 - 92
SAMPE Journal - November/December 2021 - 93
SAMPE Journal - November/December 2021 - 94
SAMPE Journal - November/December 2021 - 95
SAMPE Journal - November/December 2021 - 96
SAMPE Journal - November/December 2021 - 97
SAMPE Journal - November/December 2021 - 98
SAMPE Journal - November/December 2021 - 99
SAMPE Journal - November/December 2021 - 100
SAMPE Journal - November/December 2021 - 101
SAMPE Journal - November/December 2021 - 102
SAMPE Journal - November/December 2021 - 103
SAMPE Journal - November/December 2021 - 104
SAMPE Journal - November/December 2021 - Cover3
SAMPE Journal - November/December 2021 - Cover4
https://www.nxtbook.com/nxtbooks/sampe/journal_20240506
https://www.nxtbook.com/nxtbooks/sampe/journal_20240304
https://www.nxtbook.com/nxtbooks/sampe/journal_20240102
https://www.nxtbook.com/nxtbooks/sampe/journal_20231112
https://www.nxtbook.com/nxtbooks/sampe/journal_20230910
https://www.nxtbook.com/nxtbooks/sampe/journal_20230708
https://www.nxtbook.com/nxtbooks/sampe/journal_20230506
https://www.nxtbook.com/nxtbooks/sampe/journal_20230304
https://www.nxtbook.com/nxtbooks/sampe/journal_20230102
https://www.nxtbook.com/nxtbooks/sampe/journal_20221112
https://www.nxtbook.com/nxtbooks/sampe/journal_20220910
https://www.nxtbook.com/nxtbooks/sampe/journal_20220708
https://www.nxtbook.com/nxtbooks/sampe/journal_20220506
https://www.nxtbook.com/nxtbooks/sampe/journal_20220304
https://www.nxtbook.com/nxtbooks/sampe/journal_20220102
https://www.nxtbook.com/nxtbooks/sampe/journal_20211112
https://www.nxtbook.com/nxtbooks/sampe/journal_20210910
https://www.nxtbook.com/nxtbooks/sampe/journal_20210708
https://www.nxtbook.com/nxtbooks/sampe/journal_20210506
https://www.nxtbook.com/nxtbooks/sampe/journal_20210304
https://www.nxtbook.com/nxtbooks/sampe/journal_20210102
https://www.nxtbook.com/nxtbooks/sampe/journal_20201112
https://www.nxtbook.com/nxtbooks/sampe/journal_20200910
https://www.nxtbook.com/nxtbooks/sampe/journal_20200708
https://www.nxtbook.com/nxtbooks/sampe/journal_20200506
https://www.nxtbook.com/nxtbooks/sampe/journal_20200304
https://www.nxtbook.com/nxtbooks/sampe/journal_20200102
https://www.nxtbook.com/nxtbooks/sampe/journal_20191112
https://www.nxtbook.com/nxtbooks/sampe/journal_20190910
https://www.nxtbook.com/nxtbooks/sampe/journal_20190708
https://www.nxtbook.com/nxtbooks/sampe/journal_20190506
https://www.nxtbook.com/nxtbooks/sampe/journal_20190304
https://www.nxtbook.com/nxtbooks/sampe/journal_20190102
https://www.nxtbook.com/nxtbooks/sampe/journal_20181112
https://www.nxtbook.com/nxtbooks/sampe/journal_20180910
https://www.nxtbook.com/nxtbooks/sampe/journal_20180708
https://www.nxtbook.com/nxtbooks/sampe/journal_20180506
https://www.nxtbook.com/nxtbooks/sampe/journal_20180304
https://www.nxtbook.com/nxtbooks/sampe/journal_20180102
https://www.nxtbook.com/nxtbooks/sampe/journal_20171112
https://www.nxtbook.com/nxtbooks/sampe/journal_20170910
https://www.nxtbook.com/nxtbooks/sampe/journal_20170708
https://www.nxtbook.com/nxtbooks/sampe/journal_20170506
https://www.nxtbook.com/nxtbooks/sampe/journal_20170304
https://www.nxtbook.com/nxtbooks/sampe/journal_20170102
https://www.nxtbook.com/nxtbooks/sampe/journal_20161112
https://www.nxtbook.com/nxtbooks/sampe/journal_20160910
https://www.nxtbook.com/nxtbooks/sampe/journal_20160708
https://www.nxtbook.com/nxtbooks/sampe/journal_20160506
https://www.nxtbook.com/nxtbooks/sampe/journal_20160304
https://www.nxtbook.com/nxtbooks/sampe/journal_20160102
https://www.nxtbook.com/nxtbooks/sampe/journal_20151112
https://www.nxtbook.com/nxtbooks/sampe/journal_20150910
https://www.nxtbook.com/nxtbooks/sampe/journal_20150708
https://www.nxtbook.com/nxtbooks/sampe/journal_20150506
https://www.nxtbook.com/nxtbooks/sampe/journal_20150304
https://www.nxtbook.com/nxtbooks/sampe/journal_20150102
https://www.nxtbook.com/nxtbooks/sampe/journal_20141112
https://www.nxtbook.com/nxtbooks/sampe/journal_20140910
https://www.nxtbook.com/nxtbooks/sampe/journal_20140708
https://www.nxtbook.com/nxtbooks/sampe/journal_20140506
https://www.nxtbook.com/nxtbooks/sampe/journal_20140304
https://www.nxtbook.com/nxtbooks/sampe/journal_20140102
https://www.nxtbook.com/nxtbooks/sampe/journal_20131112
https://www.nxtbook.com/nxtbooks/sampe/journal_20130910
https://www.nxtbook.com/nxtbooks/sampe/journal_20130708
https://www.nxtbook.com/nxtbooks/sampe/journal_20130506
https://www.nxtbook.com/nxtbooks/sampe/journal_20130304
https://www.nxtbook.com/nxtbooks/sampe/journal_20130102
https://www.nxtbook.com/nxtbooks/sampe/journal_20121112
https://www.nxtbook.com/nxtbooks/sampe/journal_20120910
https://www.nxtbook.com/nxtbooks/sampe/journal_20120708
https://www.nxtbook.com/nxtbooks/sampe/journal_20120506
https://www.nxtbook.com/nxtbooks/sampe/journal_20120304
https://www.nxtbook.com/nxtbooks/sampe/journal_20120102
https://www.nxtbook.com/nxtbooks/sampe/journal_20111112
https://www.nxtbook.com/nxtbooks/sampe/journal_20110910
https://www.nxtbook.com/nxtbooks/sampe/journal_20110708
https://www.nxtbook.com/nxtbooks/sampe/journal_20110506
https://www.nxtbook.com/nxtbooks/sampe/journal_20110304
https://www.nxtbook.com/nxtbooks/sampe/journal_20110102
https://www.nxtbookmedia.com