Patent ID: 6012883
Filing Date: 2000-01-11
Classification: B23Q,B29C,B29K,Y10T

Abstract:
A method of manufacturing a hybrid lay-up tool for making a bonded and cured composite part, comprising:fabricating a master mold having a mold surface shaped and sized like said part, said mold having an ""A"" datum plane with a known relationship to said mold surface;installing reference features in said mold surface, said reference features effective to establish an orientation and location of said mold surfacelaying-up a plurality of resin-impregnated fabric plies on a facing surface of said master mold, said resin matrix having the characteristic of bonding and curing at elevated temperature to create a rigid hybrid tool face sheet for said hybrid lay-up tool;transferring said mold surface reference features to said hybrid tool face sheet;applying a vacuum bag over said plies and sealing peripheral regions of said vacuum bag around said laid-up skin and components;evacuating air from under said vacuum bag to cause air pressure outside said vacuum bag to press said vacuum bag against said plies;bonding and curing said adhesive/resin matrix to transform said plies into said rigid hybrid tool face sheet;removing said vacuum bag from said facing surface of said master mold, uncovering said rigid face sheet;attaching said hybrid tool face sheet to a base structure;machining a second ""A"" datum plane on said base structure; andremoving said hybrid tool from said machine tool bed.