Patent Description:
Support tools for manufacturing working components, such as composite aircraft parts, require custom surfaces to be generated using the support tool to support the working component. For example, during a trimming process, the working component is held in a fixture so the edges of the part can be trimmed. However, in some applications, such as in aircraft applications, the working components are very large. For example, wing components, such as the leading edge, the flaps, or other parts of the wing or fuselage of the aircraft are to be trimmed. Such components have a large surface area. To support the large working component, the support tool should be at least as large as the component.

Typically, the support tool is a large, metal plate-type support tool having a contoured surface matching the contoured surface of the component machined into the metal plate. The upper metal plate must be sufficiently thick to accommodate the contoured surface, which is expensive and has significant weight. The support tools typically include an egg-crate style metal structure having multiple components fit together and interlocking, which require custom machining operations to match the contour of the upper plate. The structures need to be assembled to support the upper plate, which can be time consuming and difficult to achieve. The resulting support tool is rather heavy and costly to manufacture.

Some small scale manufacturing processes employ additive manufactured parts. However, with large scale support tooling, the support tooling surface is too large for additive manufactured support tools to be practical. For example, the support tool itself may be unable to withstand certain forces, such as forces induced during transporting or moving of the support tool, without cracking under its own weight. Additionally, the support tool may be unable to maintain dimensional stability because the material of the support tool lacks required rigidity. For example, certain applications may require the support tool to maintain dimensional stability for the manufacturing process to be effective. One particular application is a trimming support tool that requires precise trimming of the composite part, such as for use as an aircraft wing. If the support tool is warped or damaged such that the supporting surface for the part is deflected more than an allowable tolerance, then the support tool can no longer be used for trimming the parts and a new support tool will need to be manufactured.

A tool assembly and method according to claims <NUM> and <NUM>, respectively, are provided.

The features and functions can be achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

The embodiments described herein provide an additively manufactured support tool having sufficient strength and rigidity to maintain dimensional stability within an allowable tolerance of the support tool. The following detailed description of certain embodiments will be better understood when read in conjunction with the appended drawings. It should be understood that the various embodiments are not limited to the arrangements and instrumentality shown in the drawings.

Furthermore, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments "comprising" or "having" an element or a plurality of elements having a particular property may include additional such elements not having that property.

<FIG> is a schematic illustration of a tool assembly <NUM> formed in accordance with an exemplary embodiment. The tool assembly <NUM> includes a support frame <NUM> and a support tool <NUM> supported by the support frame <NUM>. The support tool <NUM> is used to support a working component <NUM> for processing the working component <NUM> during a manufacturing process of the working component <NUM>. The support frame <NUM> is rigid and is used to transport the tool assembly <NUM>. For example, the support frame <NUM> may be lifted and moved to move the more fragile support tool <NUM>. The support frame <NUM> is used to maintain dimensional stability of the support tool <NUM> during transport within an allowable tolerance of the support tool <NUM>.

The support tool <NUM> may be customized to properly support the working component <NUM>. For example, the support tool <NUM> may have a complementary profile as the working component <NUM> for supporting the working component <NUM>. The support tool <NUM> may be contoured to receive and support the working component <NUM>. Different support tools <NUM> may be provided for processing different components <NUM>. Optionally, the support tools <NUM> may be interchanged with the support frame <NUM> to process different components <NUM>.

In an exemplary embodiment, the working component <NUM> may be a large component and the support tool <NUM> may have a large surface area to accommodate the large working component <NUM>. For example, the working component <NUM> may be an aircraft component, such as an exterior component of an aircraft. The working component <NUM> may be a portion of the skin of the aircraft. The working component <NUM> may be part of the fuselage of the aircraft. The working component <NUM> may be part of a wing of the aircraft, such as the leading edge of the wing, the flap of the wing, and the like. The working component <NUM> may be an interior component of the aircraft. The working component <NUM> may be a non-aircraft component in other various embodiments, such as a component for another type of vehicle, such as an automobile, a boat, and the like. The working component <NUM> may be a non-vehicle component in other various embodiments, such as an industrial component. Optionally, the working component is a composite part. Alternatively, the working component <NUM> may be a metal part.

The support tool <NUM> is used to support the working component <NUM> during a manufacturing process. For example, the support tool <NUM> may be used during a trimming process of the working component <NUM>. After the working component <NUM> is formed, excess material may be removed from the working component <NUM> to define a precise, repeatable shape for the working component <NUM>. The support tool <NUM> fixes the position of the working component <NUM> during processing, such as trimming. The support tool <NUM> may be used to aid the processing of the working component <NUM>. For example, the support tool <NUM> may include locating features for a forming tool <NUM> to process the working component <NUM>. The support tool <NUM> may include a router groove for guiding the forming tool <NUM> during the trimming process. The support tool <NUM> may include other features for other types of support tools to use during other processes. For example, the support tool <NUM> may be used during a pressing and forming process for the working component <NUM>. In such embodiments, the support tool <NUM> may include a mandrel or other surface that holds the working component <NUM>. The forming tool <NUM> may press the working component <NUM> during the pressing and forming process to shape the working component <NUM>. The support tool <NUM> may be used in other processes in alternative embodiments, and is not limited to the trimming process described in further detail below.

In an exemplary embodiment, the support tool <NUM> includes a faceplate <NUM> and a supporting grid structure <NUM> formed with the faceplate <NUM> is a monolithic structure. The faceplate <NUM> and the supporting grid structure <NUM> are defined by a series of additive manufactured (AM) layers <NUM> built on each other to form the support tool <NUM>. Any number of AM layers <NUM> may be provided to form the support tool <NUM>. For example, the support tool <NUM> may include <NUM> or more layers <NUM>, such as <NUM> or more layers. The faceplate <NUM> defines a supporting surface <NUM> for supporting the working component <NUM>. The support tool <NUM> extends between a top <NUM> and a bottom <NUM>. The bottom <NUM> rests on the support frame <NUM>. The top <NUM> is used to support the working component <NUM>. In an exemplary embodiment, the faceplate <NUM> is provided at the top <NUM> while the supporting grid structure <NUM> is provided at the bottom <NUM>.

In an exemplary embodiment, the AM layers <NUM> are manufactured from a thermoplastic polymer material, thermoset polymer material, or another polymer material. For example, the AM layers <NUM> may be manufactured from an Acrylonitrile-Butadiene-Styrene (ABS) material, such as a carbon filled ABS material. The AM layers <NUM> are applied or built-up using an additive manufacturing process, such as fused filament fabrication (FFF), plastic jet printing (PJP), <NUM>-D printing, powder bed processing, selective heat sintering (SHS), and the like. Additive manufacturing the support tool <NUM> may significantly reduce the fabrication cost and lead-time for fabrication as compared to metal plate type support tools. Additionally, the additive manufactured support tool <NUM> is significantly lighter weight than metal plate type support tools.

The shape and topology of the AM layers <NUM> may be designed or optimized based on supporting loads of the working component <NUM> at the surface and supporting loads of the support tool <NUM> on the support frame <NUM>. Many design constraints may be considered, such as weight and material costs, workability for forming the supporting surface for the working component <NUM>, size of the structure, strength, rigidity, deflection, and the like. While the support tool <NUM> may be manufactured from a material that is lighter weight, easier to manufacture and easier to work with as compared to a metal material, consideration must be given to how the material is handled. For example, the material may be fragile and susceptible to damage, such as from cracking or warping, particularly when the support tool <NUM> has a large area (for example, length and width compared to depth). For example, depending on the size of the support tool <NUM> (for example, relatively thin compared to length and width), the support tool <NUM> may crack under its own weight during transportation.

The support frame <NUM> is used to provide rigidity and support to the support tool <NUM>, such as during transportation, to prevent damage to the support tool <NUM>. The support frame <NUM> may be manufactured from a high-strength material, such as a steel material, that provides a rigid support for the support tool <NUM>. During transportation of the tool assembly <NUM>, the support frame <NUM> may be lifted rather than lifting directly at the support tool <NUM>. The lifting forces on the support frame <NUM> may be transferred to the support tool <NUM> in a way that the forces are dissipated through the support tool <NUM> in a manner that the support tool <NUM> is not damaged during transportation. For example, the support tool <NUM> may be thickened in the areas where the support tool <NUM> engages the support frame <NUM>. The support tool <NUM> may have arches at the attachment points with the support frame <NUM> to efficiently transfer the load between the support frame <NUM> and the support tool <NUM>.

In an exemplary embodiment, the support tool <NUM> should be designed to maintain dimensional stability. For example, the support tool <NUM> should maintain dimensions at the supporting surface for the working component <NUM> within an allowable tolerance of the support tool <NUM>. As such, the dimensions of the finished working component <NUM> after processing may be maintained from part to part throughout the life of the support tool <NUM>. In an exemplary embodiment, the tool assembly <NUM> may maintain a dimensional stability within approximately <NUM> of a designed dimension of the supporting surface <NUM> during the life of the support tool <NUM>. In some embodiments, the tool assembly <NUM> may maintain a dimensional stability of approximately <NUM> of a designed dimension of the supporting surface <NUM> during the life of the support tool <NUM>, which for support tools <NUM> having a depth of approximately <NUM> or more is an extremely small amount of deflection.

In other embodiments, such small tolerances may not be needed, depending on the working component <NUM> being processed. The support frame <NUM> maintains dimensional stability of the support tool <NUM> during transport and when resting within the allowable tolerance of the support tool <NUM>. For example, because the support frame <NUM> is rigid and the support tool <NUM> is connected to the support frame <NUM>, the support frame <NUM> maintains dimensional stability for the support tool <NUM>. The support tool <NUM> may be unable to maintain its own dimensional stability when subjected to high forces, such as the forces from lifting the tool assembly <NUM>. However, with the addition of the support frame <NUM>, the lifting forces are overcome due to the strength and rigidity provided by the support frame <NUM>. The allowable tolerance of the support tool <NUM> may be based on the material of the support tool <NUM>, the shape of the support tool, the thickness or height of the support tool <NUM>, the surface area of the support tool <NUM>, the weight of the support tool, the arrangement of the grid walls of the supporting grid structure, the thickness of the faceplate, the location of the connecting points to the support frame <NUM>, and the like.

Optionally, the faceplate <NUM> may include a seal layer <NUM> at the top <NUM>. The seal layer <NUM> may be configured to maintain a vacuum pressure at the supporting surface <NUM>. As such, when the tool assembly <NUM> includes a vacuum system for creating a vacuum pressure at the supporting surface <NUM>, the seal layer <NUM> may be used to maintain the vacuum pressure to secure the working component <NUM> to the supporting surface <NUM>. The seal layer <NUM> may be manufactured from a different material from the AM layers <NUM>, such as a material having fewer voids than the AM layers <NUM>. The seal layer <NUM> may be applied to the supporting surface <NUM> after the supporting surface <NUM> is contoured. The seal layer <NUM> may include polymer resins. The seal layer <NUM> may include a reinforcing mat, such as a fiberglass mat. The seal layer <NUM> may be a mixture of talc and plastic. Other types of seal layers <NUM> may be provided in alternative embodiments. In an exemplary embodiment, the seal layer <NUM> is non-hydroscopic to prevent water or other liquids from warping or damaging the faceplate <NUM>.

<FIG> is a perspective view of the tool assembly <NUM> in accordance with an exemplary embodiment. The tool assembly <NUM>, in the illustrated embodiment, is used as a holding fixture for trimming a surface component of an aircraft, such as a wing flap; however, the tool assembly <NUM> may be used as a holding fixture for other types of working components <NUM> and/or for other manufacturing processes other than trimming. <FIG> shows the support tool <NUM> coupled to the support frame <NUM>. The support frame <NUM> is illustrated including various features used for transporting the tool assembly <NUM>; however, the support frame <NUM> may be provided with any or all of the transporting features or other types of transporting features, while still providing support for the support tool <NUM>. The support tool <NUM> engages the support frame <NUM> such that loads are transferred between the support tool <NUM> and the support frame <NUM> to maintain dimensional stability of the support tool <NUM> during transport and when resting within an allowable tolerance of the support tool <NUM>.

In an exemplary embodiment, the support frame <NUM> includes hoist rings <NUM> for hoisting the tool assembly <NUM>, such as using a crane, lift, tractor or other machine. Any number of hoist rings <NUM> may be used. The hoist rings <NUM> may be adequately spaced apart to ensure that the tool assembly <NUM> may be lifted without damaging the support tool <NUM>. In the illustrated embodiment, the tool assembly <NUM> includes four hoist points near the four spaced apart corners of the tool assembly <NUM>. The hoist points may be positioned to balance the load of the tool assembly <NUM> during lifting, such as to retain the support tool <NUM> in a generally horizontal orientation. In the illustrated embodiment, the hoist rings <NUM> are provided near the top of the support frame <NUM> to lift the tool assembly <NUM> from above.

In an exemplary embodiment, the tool assembly <NUM> includes forklift sleeves <NUM> configured to receive forks, such as of a forklift, a crane or another machine to lift the support frame <NUM>. The forklift sleeves <NUM> may be appropriately spaced apart from each other. The forklift sleeves <NUM> may be appropriately positioned, such as near the center of the tool assembly <NUM> to balance the weight of the tool assembly <NUM> on the forks of the machine. In the illustrated embodiment, the forklift sleeves <NUM> are provided near the bottom of the support frame <NUM> to lift the tool assembly <NUM> from below.

In an exemplary embodiment, the tool assembly <NUM> includes casters <NUM> for rolling the tool assembly <NUM> along the floor. Optionally, the tool assembly <NUM> includes one or more tow bars <NUM> part of the support frame <NUM> for towing the tool assembly <NUM>. For example, tow bars <NUM> may be provided at both ends of the tool assembly <NUM>. Optionally, the casters <NUM> may be removable such that the support frame <NUM> may be bolted to the floor rather than being movable along the floor.

The support frame <NUM> includes various metal beams or other structures, which may be coupled together to form the support frame <NUM>. For example, in the illustrated embodiment, the support frame <NUM> includes support beams <NUM>, cross beams <NUM> extending between the support beams <NUM>, and support mounts <NUM> for supporting the support beams <NUM>. Other beams or components may be included in alternative embodiments. The metal material of the support frame has a stiffness and strength greater than the support tool <NUM>.

<FIG> is a bottom perspective view of a portion of the support frame <NUM> showing the support beams <NUM> and the cross beams <NUM>. <FIG> is a front perspective view of a portion of the support frame <NUM> showing the support beams <NUM> and the cross beams <NUM>. <FIG> is a rear perspective view of a portion of the support frame <NUM> showing the support beams <NUM> and the cross beams <NUM>. The support beams <NUM> and the cross beams <NUM> form a base frame <NUM> of the support frame <NUM>. The support mounts <NUM> (shown in <FIG>) may be coupled to the base frame <NUM> to support the base frame <NUM>. In other embodiments, the support mounts <NUM> may be integral or permanent parts of the base frame <NUM>, such as of the support beams <NUM> and thus form part of the base frame <NUM>.

The support beams <NUM> are used to support the support tool <NUM> (shown in <FIG>). For example, the support tool <NUM> may directly engage the support beams <NUM>. In the illustrated embodiment, two support beams <NUM> are provided, such as to support the front of the support tool <NUM> and the rear of the support tool <NUM>. However, additional support beams <NUM> may be provided in alternative embodiments. Optionally, the support tool <NUM> may additionally or alternatively directly engage the cross beams <NUM>. The cross beams <NUM> extend between and connect to the support beams <NUM> to form a rigid support frame <NUM>. The support beams <NUM> and the cross beams <NUM> may be any type of metal beams, such as hollow structural tubing, solid metal bars, I beams, channel beams, structural tees, and the like. The cross beams <NUM> may be coupled to the support beams <NUM>, such as by welding, bolting, clamping, or other attachment means.

In the illustrated embodiment, the forklift sleeves <NUM> are attached to the cross beams <NUM>, such as approximately centered between the support beams <NUM>. The forklift sleeves <NUM> may be provided below the cross beams <NUM>. The forklift sleeves <NUM> may be welded to the cross beams <NUM>; however, the forklift sleeves <NUM> may be attached by other means, such as bolting or clamping, in alternative embodiments. In the illustrated embodiment, the tow bar <NUM> is attached to the front support beam <NUM>. The tow bar <NUM> may additionally or alternatively be attached to the rear support beam <NUM>. The tow bar <NUM> may be welded to the support beam <NUM>; however, the tow bar <NUM> may be attached by other means, such as bolting or clamping, in alternative embodiments.

Each support beam <NUM> extends between a first end <NUM> and a second end <NUM>. The support beam <NUM> includes a top edge <NUM> and a bottom edge <NUM>. The support beam <NUM> includes opposite sides <NUM> extending between the edges <NUM>, <NUM> and the ends <NUM>, <NUM>. The cross beams <NUM> are attached to corresponding sides <NUM> of the support beams <NUM>. The top edge <NUM> may define a plurality of attachment points for the support tool <NUM>. For example, the support tool <NUM> may be attached to the support beams <NUM> at multiple attachment points along the top edge <NUM>.

In an exemplary embodiment, the support beam <NUM> includes attachment plates <NUM> at the first and second ends <NUM>, <NUM>. The attachment plates <NUM> may be welded to the ends <NUM>, <NUM>. The attachment plates <NUM> are used to attach the support mounts <NUM> to the support beams <NUM>. However, in alternative embodiments, the support mounts <NUM> may be directly attached to the support beams <NUM>. In an exemplary embodiment, the attachment plates <NUM> are connected to the support tool <NUM>, such as described in further detail below. The attachment plates <NUM> include bolt openings <NUM> configured to receive bolts used to connect the attachment plate <NUM> to the support mount <NUM> and/or to the support tool <NUM>. Optionally, the attachment plates <NUM> include dowel openings <NUM> configured to receive corresponding dowels to connect the attachment plate <NUM> to the support mount <NUM>, the support tool <NUM> and/or other components. The attachment plates <NUM> have a large surface area to include a plurality of the bolt openings <NUM> and/or dowel openings <NUM> to spread loads between the support mounts <NUM> and/or the support tool <NUM> with the attachment plate <NUM>. Optionally, the attachment plates <NUM> may be reinforced against the support beams <NUM>, which may enhance load transfer to the support beams <NUM>.

<FIG> is a front perspective view of the support frame <NUM> showing the base frame <NUM> and the support mounts <NUM>. <FIG> is a front perspective view of the support frame <NUM> showing the base frame <NUM> and the support mounts <NUM> attached to the base frame <NUM>. <FIG> is a rear perspective view of a portion of the support frame <NUM>. In the illustrated embodiment, the support frame <NUM> includes four support mounts <NUM> generally supporting the four corners of the tool assembly <NUM>. However, any number of support mounts <NUM> may be provided in alternative embodiments.

The support mounts <NUM> are used to support the base frame <NUM>, which is in turn used to support the support tool <NUM> (shown in <FIG>). In the illustrated embodiment, the support mounts <NUM> are discrete from the base frame <NUM> and attached thereto using bolts <NUM> configured to pass through the support tool <NUM>. In an exemplary embodiment, each support mount <NUM> includes a post <NUM> extending between a top <NUM> and a bottom <NUM>. In the illustrated embodiment, the post <NUM> has a circular cross-section; however, the post <NUM> may have other shapes in alternative embodiments, such as a rectangular shape. The hoist rings <NUM> (<FIG>) may be attached to the posts <NUM> at or near the tops <NUM>.

The support mount <NUM> includes a bolt down plate <NUM> at the bottom <NUM>. The bolt down plate <NUM> may be welded to the post <NUM>; however, the bolt down plate <NUM> may be attached to the post <NUM> by other means, such as bolting or clamping. In an exemplary embodiment, the casters <NUM> (shown in <FIG>) may be connected to the bolt down plates <NUM>, such as using bolts. However, the casters <NUM> may be removed such that the support mounts <NUM> may be attached directly to another structure, such as the floor. The bolt down plates <NUM> may be bolted directly to the floor to rigidly fix the support frame <NUM> to the floor.

The support mount <NUM> includes an attachment plate <NUM> connected to the post <NUM>, such as at or near the top <NUM>. The attachment plate <NUM> may be welded to the post <NUM>. However, the attachment plate <NUM> may be attached to the post <NUM> by other means, such as bolting or clamping. The attachment plates <NUM> are connected to the attachment plates <NUM> of the base frame <NUM> using the bolts <NUM>. In an exemplary embodiment, bushings <NUM> are positioned between the attachment plates <NUM>, <NUM>. The bushings <NUM> pass through the support tool <NUM>. The bushings <NUM> include bearing surfaces <NUM> that directly engage the support tool <NUM>. Lifting forces during transportation may be transferred from the bushings <NUM> to the support tool <NUM> through the bearing surfaces <NUM>. In an exemplary embodiment, many bolts <NUM> and corresponding bushings <NUM> are provided to spread the lifting forces to the support tool <NUM> to reduce the risk of damage to the support tool <NUM>.

In an exemplary embodiment, wear pads <NUM> (<FIG>) are provided between the attachment plates <NUM>, <NUM> and the support tool <NUM>. For example, the wear pads <NUM> may abut directly against the attachment plates <NUM>, <NUM> and the support tool <NUM> may be provided in the space between the wear pads <NUM>. The bushings <NUM> and the bolts <NUM> pass through the wear pads <NUM>. Optionally, the wear pads <NUM> may additionally include dowel openings <NUM> for receiving dowels connected to the attachment plates <NUM>, <NUM>. Optionally, the dowels may extend into the support tool <NUM>. <FIG> illustrates the tool assembly <NUM> with some components removed to illustrate the attachment plates <NUM>, <NUM> and wear pads <NUM>. For example, in the view shown, both right side support mounts <NUM> are shown, but the left side support mounts are removed to illustrate the wear pads <NUM>. Only one of the wear pads <NUM> are shown at the front end while both of the wear pads <NUM> are shown at the back end. In an exemplary embodiment, each mounting location would include two wear pads and associated attachment plates <NUM>, <NUM>.

<FIG> is a bottom view of the support tool <NUM> in accordance with an exemplary embodiment. <FIG> is a bottom perspective view of the support tool <NUM> in accordance with an exemplary embodiment. <FIG> is a bottom perspective view of the support tool <NUM>. <FIG> is a bottom perspective view of a portion of the support tool <NUM>. <FIG> is a bottom perspective view of a portion of the support tool <NUM>.

The support tool <NUM> includes the faceplate <NUM> and the supporting grid structure <NUM> extending from a bottom <NUM> of the faceplate <NUM>. The supporting grid structure <NUM> is formed with the faceplate <NUM> is a monolithic structure. The supporting grid structure <NUM> and the faceplate <NUM> are formed from the many AM layers built-up using an additive manufacturing process. In an exemplary embodiment, the bottom <NUM> of the faceplate <NUM> is contoured to complement the contoured shape of the supporting surface <NUM> at the top <NUM> of the faceplate <NUM>. As such, the amount of material usage may be reduced, thus reducing the cost of the support tool <NUM> and the weight of the support tool <NUM>.

The supporting grid structure <NUM> includes a plurality of grid walls <NUM> defining cavities <NUM> below the faceplate <NUM>. In an exemplary embodiment, the grid walls <NUM> extends to bottom edges <NUM> defining a base plane <NUM> at the bottom <NUM> of the support tool <NUM>. The support tool <NUM> may rest on the base frame <NUM> (shown in <FIG>) at the base plane <NUM>. For example, at least some of the bottom edges <NUM> may directly engage the base frame <NUM>. Lifting forces may be transferred from the base frame <NUM> to the support tool <NUM> through the bottom edges <NUM> resting on the base frame <NUM>. The forces may be spread through the supporting grid structure <NUM> to the faceplate <NUM>. For example, the forces may be spread along the grid walls <NUM>.

In an exemplary embodiment, at least some of the grid walls <NUM> include brace walls <NUM> extending therefrom below the base plane <NUM>. The brace walls <NUM> are configured to engage the base frame <NUM> (for example, the support beams <NUM>). Optionally, the brace walls <NUM> may be curved or arced to transfer loads and forces into the grid walls <NUM>. In an exemplary embodiment, the brace walls <NUM> include pockets <NUM> that receive corresponding support beams <NUM>. The brace walls <NUM> may extend along sides <NUM> of the support beams <NUM>. Optionally, the bottom edges <NUM> of corresponding grid walls <NUM> may be exposed in the pockets <NUM> such that the bottom edges <NUM> may directly engage the support beam <NUM>. The brace walls <NUM> define brackets <NUM> configured to engage the support beams <NUM> at multiple attachment points. The brackets <NUM> transfer loads or forces between the support tool <NUM> and the base frame <NUM>.

The support tool <NUM> includes first and second side walls <NUM>, <NUM> extending generally lengthwise along the support tool <NUM> and first and second end walls <NUM>, <NUM> extending generally widthwise across the support tool <NUM>. In the illustrated embodiment, the length of the support tool <NUM> is longer than the width of the support tool <NUM>. Optionally, the side walls <NUM>, <NUM> may be non-planar. For example, the support tool <NUM> may be wider at the first end wall <NUM> and narrower at the second end wall <NUM>. Optionally, the end walls <NUM>, <NUM> may be non-planar. For example, the first side wall <NUM> of the support tool <NUM> may be shorter than the second side wall <NUM>. The side walls <NUM>, <NUM> and/or the end walls <NUM>, <NUM> may include multiple segments angled relative to each other. The dimensions of the side walls <NUM>, <NUM> and the end walls <NUM>, <NUM> may be selected to accommodate the shape of the working component <NUM> (shown in <FIG>). For example, when working with a curved wing component of an aircraft, the component may taper from a root or base to a tip of the wing component. The faceplate <NUM> needs to be wider at the first end wall <NUM> to accommodate the wider portion of the wing component while the faceplate <NUM> is able to be narrower at the second end wall <NUM>. Reducing the dimensions where allowed reduces the overall material and the overall weight of the support tool <NUM>.

The grid walls <NUM> may be designed to accommodate the non-uniform shape of the support tool <NUM>. For example, longitudinal grid walls 202a may extend generally lengthwise along the side walls <NUM>, <NUM> between the end walls <NUM>, <NUM>, while lateral grid walls 202b may extend generally widthwise along the end walls <NUM>, <NUM> between the side walls <NUM>, <NUM>. Some of the longitudinal grid walls 202a may be parallel to each other, while other longitudinal grid walls 202a may be nonparallel to each other. Some of the lateral grid walls 202b may be parallel to each other, while other lateral grid walls 202b may be nonparallel to each other. In the illustrated embodiment, the longitudinal grid walls 202a at the brace walls <NUM> are parallel to each other and are perpendicular to the lateral grid wall <NUM> that rests on the support beam <NUM>. Optionally, some of the longitudinal grid walls 202a may have different thicknesses and some of the lateral grid walls 202b may have different thicknesses. Optionally, the side walls <NUM>, <NUM> and/or the end walls <NUM>, <NUM> may have similar thicknesses to the grid walls <NUM>. Alternatively, the side walls <NUM>, <NUM> and/or the end walls <NUM>, <NUM> may be thicker than the grid walls <NUM>.

In an exemplary embodiment, the support tool <NUM> includes mounting pads <NUM> for attaching to the support frame <NUM>. For example, the mounting pads <NUM> may be connected to the attachment plates <NUM>, <NUM>. The mounting pads <NUM> are received in the space between the attachment plates <NUM>, <NUM>. The mounting pads <NUM> engage the support mounts <NUM> and/or the support beams <NUM> (such as through the wear pads <NUM>) such that loads are transferred between the support tool <NUM> and the support frame <NUM> through the mounting pads <NUM>. The mounting pads <NUM> may be compressed between the attachment plates <NUM>, <NUM> such that the mounting pads <NUM> are secured between the attachment plates <NUM>, <NUM> by a compression fit. The mounting pads <NUM> include bolt openings <NUM> for receiving the bolts <NUM> and the bushings <NUM>. In an exemplary embodiment, the mounting pads <NUM> include dowel openings <NUM> for receiving dowels from the attachment plates <NUM> and/or <NUM>.

In an exemplary embodiment, the mounting pads <NUM> are aligned with the brace walls <NUM> such that the mounting pads <NUM> are aligned with the support beams <NUM>. The mounting pads <NUM> extend below the base plane <NUM> in the illustrated embodiment. The mounting pads <NUM> have increased height and thickness compared to other portions of the side walls <NUM>, <NUM> to support the load transfer between the support tool <NUM> and the support frame <NUM>. The mounting pads <NUM> are formed with the supporting grid structure <NUM> as part of the monolithic structure. The mounting pads <NUM> are built into the side walls <NUM>, <NUM> as part of the AM layers during the additive manufacturing process.

<FIG> is a top perspective view of the tool assembly <NUM> showing the supporting surface <NUM> of the faceplate <NUM> of the support tool <NUM>. <FIG> is a top view of the tool assembly <NUM>. The supporting surface <NUM> is sized and shaped to accommodate the working component <NUM> (shown in <FIG>). The support tool <NUM> is a large area support tool for working with large working components <NUM>. To reduce the weight of the support tool <NUM>, the support tool <NUM> may be relatively thin (for example, small height) as compared to a length and a width of the support tool <NUM>. For example, the support tool <NUM> may have a width of at least <NUM> and a length of at least <NUM>, while having a depth of at least <NUM>. In various embodiments, the support tool <NUM> may have a width of approximately <NUM> and a length of approximately <NUM>, while having a depth of approximately <NUM>; however, the support tool <NUM> may have any appropriate dimensions to accommodate the working component <NUM>.

The large surface area along with the relatively thin depth makes the support tool fragile and susceptible to damage, such as from cracking or warping. Cracking or warping causes the supporting surface to become dimensionally unstable, such as by shifting one or more portions of the supporting surface out of manufacturing tolerance. If the support tool is dimensionally unstable, it is unsuitable for manufacturing the working component. For example, the trimming operation would lead to improperly shaped aircraft wing components, which would be unusable for building the aircraft. In some embodiments, the allowable tolerance for maintaining dimensional stability is extremely small. For example, in various embodiments, a dimensional stability of within approximately <NUM> of a designed dimension of the supporting surface <NUM> is to be maintained during the life of the support tool <NUM>. In some embodiments, the tool assembly <NUM> is to maintain a dimensional stability of approximately <NUM> of a designed dimension of the supporting surface <NUM> during the life of the support tool <NUM>, which for support tools <NUM> having a depth of approximately <NUM> or more is an extremely small amount of deflection. The support frame <NUM> maintains the dimensional stability of the more fragile support tool <NUM> by rigidly holding the support tool <NUM>.

In the illustrated embodiment, the supporting surface <NUM> is non-planar. For example, the supporting surface <NUM> includes a well <NUM> in the top <NUM> that receives the working component <NUM>. The supporting surface <NUM> is curved to accommodate the curved surface of the aircraft wing component. In the illustrated embodiment, the well <NUM> is wider at the first end wall <NUM> of the support tool <NUM> and is narrower at the second end wall <NUM> of the support tool <NUM>. Additionally, in the illustrated embodiment, the well <NUM> is curved between the front and rear ends. For example, a first side <NUM> of the well <NUM> may be curved and/or a second side <NUM> of the well <NUM> may be curved. Optionally, the well <NUM> may be open at the front and rear ends of the support tool <NUM>. As such, fluid may be allowed to flow out of the well <NUM> during the manufacturing process.

In an exemplary embodiment, the tool assembly <NUM> includes a vacuum assembly <NUM> (<FIG>). The vacuum assembly <NUM> maintains a vacuum pressure at the supporting surface <NUM> to hold the working component <NUM> on the supporting surface <NUM>. The vacuum assembly <NUM> includes a vacuum generator <NUM> and a plurality of vacuum lines <NUM> extending to the supporting surface <NUM>. In an exemplary embodiment, the vacuum lines <NUM> extend below the support tool <NUM>, through the supporting grid structure <NUM> to the faceplate <NUM>. The faceplate <NUM> includes a plurality of ports <NUM> extending therethrough. The vacuum lines <NUM> extend into or to the ports <NUM> to maintain a vacuum pressure at the supporting surface <NUM>. In an exemplary embodiment, the support tool <NUM> includes a plurality of discrete vacuum areas <NUM> along the supporting surface <NUM>. Each vacuum area <NUM> includes at least one port <NUM> connected to corresponding vacuum line <NUM>. Seals <NUM> surround each vacuum area <NUM>. The seals <NUM> may seal to the working component <NUM> to create a vacuum within the corresponding vacuum area <NUM>.

<FIG> is a bottom view of the tool assembly <NUM> in accordance with an exemplary embodiment. <FIG> is another bottom view of the tool assembly <NUM>. <FIG> is a bottom perspective view of the tool assembly <NUM>. <FIG> is a side view of the tool assembly <NUM>. <FIG> is another side view of the tool assembly <NUM>. The vacuum assembly <NUM> is illustrated in <FIG> and <FIG> extending along the second side wall <NUM>. The vacuum lines <NUM> may be routed below the support tool <NUM>, such as into the cavities <NUM> for connection to the faceplate <NUM>.

The support tool <NUM> is shown coupled to the support frame <NUM>. When assembled, the support tool <NUM> rests on the support beams <NUM>. For example, the brackets <NUM> engage the support beams <NUM> at attachment points <NUM> along the top edge <NUM> and sides <NUM> of the support beams <NUM>. The support beams <NUM> are received in the pockets <NUM>. Loads or forces are transferred between the support beams <NUM> and the supporting grid structure <NUM> through the grid walls <NUM>. Optionally, the cross beams <NUM> may be located slightly below the base plane <NUM> such that the cross beams <NUM> do not interfere with the supporting grid structure <NUM>. The cross beams <NUM> do not receive direct loads from the supporting grid structure <NUM>, but rather rigidly support and hold the support beams <NUM>.

In an exemplary embodiment, the support tool <NUM> is connected to the support frame <NUM> using the bolts <NUM>. For example, the attachment plates <NUM> are connected to the interior surfaces of the mounting pads <NUM> and the attachment plates <NUM> are connected to exterior surfaces of the mounting pads <NUM>. The bolts <NUM> extend entirely through the structure to connect the attachment plates <NUM>, <NUM>.

<FIG> is a sectional view of a portion of the tool assembly <NUM>. <FIG> is another sectional view of a portion of the tool assembly <NUM>. <FIG> is a bottom sectional view of a portion of the tool assembly <NUM>. The support tool <NUM> is mounted to the support frame <NUM>. The support grid structure <NUM> supports the faceplate <NUM>. The faceplate <NUM> may be relatively thin to reduce material weight and cost. The grid walls <NUM> are spaced apart an appropriate distance to support the faceplate <NUM> based on the weight of the working component <NUM> and the type of manufacturing process being performed. Optionally, the bottom <NUM> of the faceplate <NUM> may be curved such that the grid walls <NUM> have different heights measured between the base plane <NUM> and the bottom <NUM> of the faceplate <NUM>.

As shown in <FIG>, the brackets <NUM> receive the support beam <NUM> in the pockets <NUM>. The grid walls <NUM> may rest directly on the support beam <NUM> to transfer loads between the support frame <NUM> and the support tool <NUM>. The mounting pads <NUM> are connected to the attachment plate <NUM>, <NUM> using the bolts <NUM> and the bushings <NUM>. The bushings <NUM> pass through the wear pads <NUM> and the mounting pad <NUM>. The bolts <NUM> pass through the attachment plates <NUM>, <NUM> and the bushings <NUM> to secure the mounting pad <NUM> to the attachment plates <NUM>, <NUM>. As such, loads may be transferred between the support mounts <NUM>, the support beams <NUM> and the support tool <NUM>.

In an exemplary embodiment, the support tool <NUM> is removable from the support frame <NUM>. For example, the bolts <NUM> may be unbolted to remove the support mounts <NUM> from the support tool <NUM> and/or from the base frame <NUM>. The support tool <NUM> may then be lifted off of the base frame <NUM> and replaced with a different support tool <NUM>, such as a support tool having a different faceplate for supporting a different working component or a different faceplate for performing a different process. The support frame <NUM> thus defines a common supporting structure for different support tools <NUM>. The various support tools may have common features, such as the layout of the mounting pads <NUM> and the brace walls <NUM>. As such, the support tools may have common datum points for connecting to the same rigid support frame <NUM>, but may include a different faceplate and a different supporting grid structure with at least some common features for mounting to the support frame <NUM>.

In other various embodiments, some components of the support frame <NUM> are removable, while other components are not removable. For example, the support mounts <NUM> may be removable from the base frame <NUM> and the support tool to be used with a different support tool. In such embodiments, the support mounts may remain mounted to the floor and different support tools transported on different base frames may be interchanged with the support mounts. In other various embodiments, the support tool <NUM> may be removed from the base frame <NUM>, but the support mounts <NUM> may remain attached to the support tool <NUM>. In such embodiments, the support mounts <NUM> may include both attachment plates <NUM>, <NUM> sandwiching the mounting pad <NUM> and the interior attachment plates may be attachable to and detachable from the base frame <NUM>. In such embodiments, the base frame is reusable with different support tools <NUM>.

<FIG> illustrates the support tool <NUM> during manufacture. The support tool <NUM> is manufactured in a series of additive manufactured layers built on each other to form the support tool <NUM>. In an exemplary embodiment, the support tool <NUM> is built upside down with the faceplate <NUM> on a build surface <NUM>. The layers are built up with the supporting grid structure <NUM> built on the faceplate <NUM>. In an exemplary embodiment, the support tool <NUM> is manufactured with the faceplate <NUM> being planar on the planar build surface <NUM>. Portions of the faceplate <NUM> are later removed to form the desired contoured supporting surface <NUM> (shown in <FIG>). After the support tool <NUM> is formed, the support tool <NUM> may be connected to the support frame <NUM> (shown in <FIG>). Other processes may be used in alternative embodiments to form the support tool <NUM> as a monolithic structure.

Optionally, the support tool <NUM> may be formed by embedding smart scepters, such as heating elements, into the AM layers to create an activity heated support tool <NUM>. The support tool may be formed with sensors embedded therein or attached thereto, such as strain gauges for sensing strains in the support tool <NUM> or position sensors for sensing relative positions and thus deflection amounts for the support tool <NUM>. According to the invention, metallic components and/or fiber components are embedded in the support tool to improve material properties of the AM material forming the AM layers, such as to enhance structural stiffness to maintain dimensional stability during support tool handling or transportation.

<FIG> illustrates the tool assembly <NUM> mounted to a floor <NUM>. The support tool <NUM> is shown coupled to the support frame <NUM>. The support frame <NUM> is mounted to the floor <NUM>. For example, the bolt down plates <NUM> of the support mounts <NUM> may be bolted to the floor <NUM>. In an exemplary embodiment, after the tool assembly <NUM> is fixed to the floor <NUM>, the faceplate <NUM> may be machined to form the supporting surface <NUM>. For example, material of the faceplate <NUM> may be removed to form the contoured shape of the supporting surface <NUM>.

<FIG> is a top perspective view of a portion of the tool assembly <NUM> showing the supporting surface <NUM> at the front end of the support tool <NUM>. <FIG> is a top perspective view of a portion of the tool assembly <NUM> showing the supporting surface <NUM> at the rear end of the support tool <NUM>. The well <NUM> is formed in the faceplate <NUM> having a complementary shape to the working component <NUM> (shown in <FIG>). Seal grooves <NUM> are machined in the supporting surface <NUM> to receive the seals <NUM> (shown in <FIG>). Optionally, one of the seal grooves <NUM> may extend the length of the well <NUM> along the first side <NUM> while another of the seal grooves <NUM> may extend the length of the well <NUM> along the second side <NUM>. Vacuum channels <NUM> are machined in the vacuum areas <NUM> to maintain a vacuum pressure in the vacuum areas <NUM>. The vacuum channels <NUM> are open to corresponding ports <NUM> such that the vacuum may be dispersed throughout the vacuum area <NUM>.

In an exemplary embodiment, the support tool <NUM> may include one or more support tool surfaces <NUM> to support the forming tool <NUM> (shown in <FIG>) during the manufacturing process. For example, the forming tool <NUM> may be a router and the support tool surface <NUM> may be a surface along which the router is moved for trimming the working component <NUM>. Other types of support tool surfaces may be provided in alternative embodiments, such as for different types of manufacturing processes.

<FIG> is a bottom perspective view of the tool assembly <NUM> in accordance with an exemplary embodiment. The support tool <NUM> is shaped differently than embodiments shown above. For example, the support tool <NUM>, in the illustrated embodiment, does not include side walls and end walls. In contrast, the grid walls <NUM> of the supporting grid structure <NUM> are exposed at the sides and ends of the support tool <NUM>. The grid walls <NUM> may be thinner than embodiments shown above. The grid walls <NUM> may have non-uniform heights. The support tool <NUM> may have reduced material to reduce the cost and weight of the support tool <NUM>. However, the support tool <NUM> may be more fragile than embodiments having side walls and/or end walls.

The support frame <NUM> is shaped differently than the support frame illustrated above. However, the support tool <NUM> may be connected to the support frame <NUM> in a similar manner as described above, such as connecting the brackets <NUM> on the support beams <NUM> and connecting the mounting pads <NUM> to the attachment plates <NUM>, <NUM>. In the illustrated embodiment, the support mounts <NUM> are smaller and have fewer connection points. Additionally, each attachment plate <NUM> is located near the bottom <NUM> of the post <NUM>. The post <NUM> includes right angle beams near the top <NUM> to locate the top <NUM> and the hoist rings <NUM> above the faceplate <NUM>. In the illustrated embodiment, the support frame <NUM> includes tow bars <NUM> at both the front and the rear of the tool assembly <NUM>.

<FIG> is a flow chart of one embodiment of a method <NUM> for manufacturing a tool assembly in accordance with the subject matter herein. The method <NUM> can be performed to manufacture the tool assembly <NUM> used for processing the working component <NUM>.

At <NUM>, the method includes building a support tool on a build surface by an additive manufacturing process. The additive manufacturing process is used to build up the support tool in layers. For example, during manufacture, the process is used to build a faceplate and the supporting grid structure as a monolithic structure. Optionally, the support tool may be built upside down with the faceplate on the build surface and the supporting grid structure layered above the faceplate. The supporting grid structure includes a plurality of grid walls extending in different directions, such as generally longitudinally and laterally across the faceplate to support the faceplate. Cavities are defined between the grid walls. By forming a grid structure as opposed to a solid structure, the amount of material may be reduced, decreasing the weight and the cost of the support tool. In various embodiments, the layers may be manufactured from a thermoplastic or thermoset polymer material, such as an ABS material. The material may have fillers, such as metal fillers, carbon fillers and the like. Any type of additive manufacturing process may be used, such as fused filament fabrication (FFF), plastic jet printing (PJP), <NUM>-D printing, powder bed processing, selective heat sintering (SHS), and the like. The shape and topology of the layers forming the faceplate and the supporting grid structure may be designed or optimized based on supporting loads of the working component at the surface and supporting loads of the support tool on a support frame.

At <NUM>, the method includes providing a support frame for the support tool. The support frame is rigid and protects the support tool, such as during transportation. In various embodiments, the support frame is provided with support beams, cross beams between the support beams, and support mounts for supporting the support beams. The support mounts may be discrete from the support beams and connected thereto, such as by bolts, clamps, and the like. Alternatively, the support mounts may be extensions of the support beams, welded to the support beams, or integral with the support beams. The support beams may include many attachment points for attaching the support tool to the support frame.

At <NUM>, the method includes attaching the supporting grid structure of the support tool to the support beams such that the support frame rigidly holds the support tool. The support tool may rest directly on the support beams. For example, the grid walls may have brackets formed therewith that may include pockets, which receive and engage the support beams. In various embodiments, the support tool may include mounting pads formed with the supporting grid structure that are connected to the support beams and/or the support mounts. For example, the support beams and the support mounts may include attachment plates connected together by bolts. The mounting pads may be positioned between the attachment plates and the bolts may pass through the mounting pads. The mounting pads may rest on the bolts, or bushings surrounding the bolts, for direct engagement between the support tool and the support frame. Loads or forces may be transferred between the support tool and the support frame at the attachment points where the support tool directly engages the support frame. The support frame provides rigidity to the support tool to maintain dimensional stability of the support tool, such as during transport, and even when resting. The rigid support frame does not allow the support tool to deflect outside of an allowable tolerance of the support tool. The support frame may prevent cracking or damage of the support tool during loading of the support tool, processing of the working component, or transport of the support tool.

At <NUM>, the method includes forming the faceplate of the support tool by removing portions of the faceplate to form a supporting surface for supporting the working component for processing on the supporting surface. The faceplate may be machined to remove portions of the faceplate to form the contoured supporting surface.

<FIG> is a flow chart of one embodiment of a method <NUM> for transporting a tool assembly in accordance with the subject matter herein. The method <NUM> can be performed to transport the tool assembly <NUM> used for processing the working component <NUM>.

At <NUM>, the method includes attaching a support tool to a support frame by coupling a supporting grid structure of the support tool to support beams of the support frame. The support tool may be manufactured by the method described above with reference to <FIG>. For example, the support tool may be manufactured by an additive manufacturing process used to build up the support tool in layers to build the faceplate and the supporting grid structure as a monolithic structure. The support frame may be manufactured by attaching cross beams between the support beams to provide rigidity to the base frame of the support frame. Support mounts may be connected to the support beams, such as using bolts between attachment plates of the support beams and the support mounts. The bolts may pass through mounting pads of the support tool to attach the support tool to the support frame. The support tool may rest directly on the support beams, such as by forming brackets in the supporting grid structure.

At <NUM>, the method includes lifting the support frame and moving the support frame to move the more fragile support tool. The support frame may include a number of lift points. The support frame transfers the lifting forces to the support tool. The lifting forces are then dissipated through the supporting grid structure to balance the lifting forces across the large area of the support tool. The support frame may include hoist rings for hoisting the support frame, such as using a crane. The support frame may include forklift sleeves configured to receive forks of a forklift to transport the tool assembly. The support frame may include castors for rolling the tool assembly along the floor. The support frame may include a tow bar for towing the tool assembly, such as on the castors. At <NUM>, the method includes maintaining dimensional stability of the more fragile support tool within an allowable tolerance of the support tool using the rigid support frame.

Claim 1:
A tool assembly (<NUM>), comprising:
a support frame (<NUM>), support beams (<NUM>), and support mounts (<NUM>), the support mounts (<NUM>) supporting the support beams (<NUM>), the support frame (<NUM>) being rigid and used to transport the tool assembly (<NUM>); and
a support tool (<NUM>) for aircraft parts, supported by the support frame (<NUM>), the support tool (<NUM>) comprising:
a faceplate (<NUM>) and a supporting grid structure (<NUM>), formed with the faceplate (<NUM>) as a monolithic structure; and
metallic and/or fiber components embedded in the support tool to enhance structural stiffness to maintain dimensional stability during support tool handling and transportation,
wherein:
the faceplate (<NUM>) and the supporting grid structure (<NUM>) are defined by a series of additive manufactured, AM, layers (<NUM>), built on each other;
the supporting grid structure (<NUM>) is positioned below the faceplate (<NUM>) and supporting the faceplate (<NUM>);
the faceplate (<NUM>) comprises a supporting surface (<NUM>) at a top (<NUM>) of the support tool (<NUM>) for supporting a working component (<NUM>); and
the supporting surface (<NUM>) is contoured and defined by a well (<NUM>), formed in top-most ones of the AM layers (<NUM>);
the supporting grid structure (<NUM>) engages the support beams (<NUM>) such that loads are transferred between the support tool (<NUM>) and the support frame (<NUM>) through the support beams (<NUM>); and
the support frame (<NUM>) maintains dimensional stability of the support tool (<NUM>) during transport and when resting within an allowable tolerance of the support tool (<NUM>).