Patent ID: 7858012
Filing Date: 2010-12-28
Classification: B29C,B29L

Abstract:
1. A method of producing a fuselage structure of an aircraft, comprising in sequence: manufacturing a male mold from an epoxy foam material that permanently deforms at or below an upper limit temperature that is no greater than 180° F., using computer numerically controlled machining; adding a plurality of composite layers to the male mold to create a female tool; at least partially curing the female tool at a primary cure temperature below the upper limit temperature, while at least a portion of the female tool is coupled to at least a portion of the male mold; separating at least the portion of the female tool from the portion of the male mold; curing the female tool at a secondary cure temperature above the upper limit temperature; using an automated composite layup machine to deposit composite material on the female tool, in a freestanding fashion, to create the fuselage structure; and hand touching up the fuselage structure to meet a specification.