Automated prototyping of a composite airframe

Details Automated prototyping of a composite airframe Automated prototyping of a composite airframe

2009-03-03

2010-12-28

Johnson, Christina (Department: 1791)

Plastic and nonmetallic article shaping or treating: processes

Mechanical shaping or molding to form or reform shaped article

To produce composite, plural part or multilayered article

C264S240000, C264S241000, C264S247000, C264S272130, C264S259000, C264S260000

Reexamination Certificate

active

07858012

ABSTRACT:
A high quality finished prototype fuselage structure of an aircraft is manufactured using a cured female tool and an automated composite layup machine, and then touched up by hand to meet a tolerance or other specification. The female tool is preferably made from a male mold, by depositing layers of composite material over the mold, curing the tool together at a first cure temperature, separating the tool from the mold, and then curing the tool at a second, higher temperature. The first cure temperature should be at or below an upper limit temperature no greater than 180° F. The second cure temperature is preferably in the range of 250° F. to 350° F. The step of hand touching up can comprise one or more of mechanically abrading and deforming a first portion of the fuselage structure to mate with a second portion of the fuselage structure.

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