Patent ID: 11969960
Assignee: THE BOEING COMPANY
Field: Other special machines (Mechanical engineering)
Classification: CPC B  Y | IPC B

Claim 9:
10. A method of fabricating a composite part, the method comprising:
placing composite layers on a molding tool to form a layup, wherein at least a portion of the layup is within a constrained space created by a shape of the molding tool;
heating the molding tool and the layup in a curing device, wherein the heating activates a foamable material to expand within the constrained space into an expanded material that presses the layup against the forming surfaces of the molding tool, and cures the layup to form the composite part;
boring a hole through the expanded material after curing;
threading a cutting wire through the hole in the expanded material;
controlling a manipulator comprising a robotic arm, with a controller, to perform automated tasks of:
grasping opposing ends of the cutting wire with end effectors that make an electrical coupling with the cutting wire;
heating the cutting wire with current applied through the cutting wire via the electrical coupling; and
moving the cutting wire while heated within the constrained space to cut the expanded material into pieces; and

removing the pieces from the constrained space.